High speed manufacturing system

ABSTRACT

A high speed manufacturing system for processing articles of manufacture requiring processes to be performed on the articles at a pre-selected processing rate includes a trunk for simultaneously conveying a plurality of the articles of manufacture at the pre-selected processing rate in a first mode of motion from the beginning of the manufacturing system to the end of the system. At least one branch processing station is positioned intermediate the beginning and the end of the trunk wherein the branch processing station during its operation performs at least one process on articles of manufacture conveyed on the branch processing station and where the articles are conveyed in a second mode of motion. At least one transfer device is positioned intermediate the trunk and the branch processing station to continuously extract articles of manufacture from the trunk and transition the movement of the extracted articles of manufacture from the first mode of motion to the second mode of motion for transfer to the branch processing station. The transfer device also extracts each of the processed articles of manufacture from the branch processing station and transitions the movement of the articles from the second mode of motion to the first mode of motion for transfer to the trunk.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a divisional of U.S. application Ser. No.09/815,319, filed on Mar. 22, 2001, which is a divisional of Ser. No.09/317,577, filed on May 24, 1999, which claims the benefit of U.S.Provisional Application Serial No. 60/090,860, filed on Jun. 26, 1998,the entire disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a processing system for smallitems of manufacture and, in particular, to a modular processing systemfor the production of batteries.

[0003] Items of manufacture, and, in particular, small items ofmanufacture requiring multiple processes during their production andwhich are produced in large quantities, such as dry cell batteries, arecompleted by passing the articles through a series of individualapparatuses which are specifically designed to perform one or twoprocesses. These processing machines are often stand-alone units whichoperate on a bulk input/bulk output basis. This type of system is laborintensive, and lacks the capability for adequate quality control, rapidmaintenance, or tracking of the manufactured articles.

[0004] Current processing equipment which typically operates in anindexed manner has a single main drive motor which drives the indexer aswell as driving the application heads performing the specific process.These various operations conducted by the machines are mechanicallytimed and are controlled by mechanical cams. Such mechanical timing istime-consuming to setup, is not flexible, and may lack precision. Anymalfunction of these machines generally requires the entire machine tobe pulled off-line for time-consuming repair, thus resulting inundesirable production efficiency.

[0005] The bulk-in/bulk-out manner in which these machines operate issuch that the battery cans are extracted in random fashion from a binthereby requiring proper orientation to begin the processing and arethen output from the machine into another bin after processing. Theprocessed cans are then transported in bulk to another processingstation whereupon the bin extraction and article orientation functionsare again repeated thus duplicating unnecessary handling and timeconsuming operations. Others of these machines operate on a theory ofback pressure wherein the battery cans are stacked and urged to aprocessing station by applying a force to the backed up cans to forcethe articles through the processing machine. There must always be asupply of battery cans on the input side to maintain sufficient pressureto keep the ‘pump primed’ thereby facilitating processing throughput.Such methods of input and output preclude the tracking of individualbattery cans during processing and between discrete machines. Themanufacturer therefore loses information about individual cans betweenproduct assembly or processing steps. A consequence of the random inputand output is a loss of quality control on individual articles with theresult being that there is little to no process data available on thearticles, and what data is available is not in alignment with qualitycontrol samples taken from the processing line.

[0006] At the conclusion of the quality control sampling, the machine isagain stopped and again unloaded by hand. This time-consuming butnecessary function often results in a significant loss of valuableproduction time in addition to the excessive labor costs associatedtherewith. Additionally, repeated starting and stopping of the machineinduces variation in the production process which can adversely affectproduction quality.

[0007] The current mechanically controlled machines often include one ormore cams to transfer desired time sequenced motion to the processingapparatuses mounted to the machine for a desired synchronized operation.In addition to the single drive motor driving the processing apparatus,the motor also operates and drives a large mass circular dial whichtransports the battery cans therearound to the individual processstations on the machine. Typically, these large mass dials require asignificant percentage of the power consumed by the machine toaccelerate and decelerate the dial during the indexing operations. Powerthus expended contributes little ‘value added’ to the finished product.Also, the acceleration and deceleration of large mass dials requires asignificant portion of the total time of operation which thereforeseverely limits the throughput of the processing machines.

[0008] The aforementioned current processing equipment employsseparately controlled process stations in which battery cans wererandomly dumped from one machine to another, thereby eliminating anyability to track a given battery can. Additionally, in order to conductexperimental process operations, conventional manufacturing systemscommonly require that the normal system operation first be shutdown, theexperimental equipment then be installed, and the experimental processthereafter conducted. Once the experimental operation is finished, theconventional system is reconfigured for normal article manufacturing.Thus, experimental processing required extensive shutdown time and laborto reconfigure the system and conduct the experimental process.

[0009] Therefore, there is a desire and need in industry andparticularly in dry cell battery processing for a processing systemwhich can operate at increased throughput and which eliminatesunnecessary handling and duplicative operations to be performed on themanufactured articles. The needed processing system has the additionalcharacteristics of being flexible, permitting off-line set-up andcalibration, the ability to be quickly deployed, and capable of rapidlyincorporating product design changes. Such a system is also desired tomore efficiently monitor quality control on processes, including thecapability of tracking a single item of manufacture through theprocessing system, and also the ability to test new processes andprocessing equipment for a comparative analysis of articles ofmanufacture processed normally with articles of manufacture processedwith one or more test processes.

[0010] Also, it is desirable to provide for a processing system thatallows for battery cans to be tracked and accounted for throughout theentire processing operation. Further, it is desirable to provide forsuch a processing system that allows for easy experimental processingthat does not require excessive system shutdown and labor.

SUMMARY OF THE INVENTION

[0011] One aspect of the present invention is a high speed manufacturingsystem for processing articles of manufacture wherein processes are tobe performed on the articles at a pre-selected processing rate. Thesystem includes a trunk for simultaneously conveying a plurality of thearticles of manufacture at the pre-selected processing rate in a firstmode of motion from the beginning of the manufacturing system to the endof the system. At least one branch processing station is positionedintermediate the beginning and the end of the trunk. The branchprocessing station, during its operation, performs at least one processon the articles of manufacture conveyed on the branch processing stationwherein the articles are conveyed in a second mode of motion. At leastone transfer device is positioned intermediate the trunk and the branchprocessing station to continuously extract articles of manufacture fromthe trunk and transition the movement of the extracted articles ofmanufacture from the first mode of motion to the second mode of motionfor transfer to the branch processing station. The transfer device alsoextracts each of the processed articles of manufacture from the branchprocessing station and transitions the movement of the articles from thesecond mode of motion to the first mode of motion for transfer to thetrunk.

[0012] Another aspect of the present invention is a distributed controlsystem for controlling the manufacturing system having a trunk and atleast one branch processing station. The distributed control systemincludes a coordinating controller for monitoring processing of eacharticle of manufacture on the manufacturing system and for coordinatingthe processing of each article of manufacture. A process stationcontroller is networked with the coordinating controller and isassociated with each branch processing station for initiating theprocesses performed thereon for each article of manufacture. A processmodule controller is associated with each individual process module oneach processing station and is networked with the process stationcontroller. The process module coordinator controls the processingoperation of the associated process module wherein the controlcoordinator coordinates the processing operation of each article ofmanufacture, the processing controller initiates control operations, andthe process module coordinator performs individual control operationsassociated with each process module.

[0013] Yet another aspect of the present invention is a method forprocessing articles of manufacture comprising the steps of conveying aplurality of articles of manufacture in a substantially continuousmotion from a beginning of a manufacturing system to an end of themanufacturing system; transferring the plurality of articles ofmanufacture sequentially onto a branch processing station; conveying theplurality of articles of manufacture on the branch processing station inan indexed intermittent motion to provide a dwell operation and anindexed operation; and performing at least one process on the articlesof manufacture during the dwell operation.

[0014] Yet another aspect of the present invention is a transfer devicefor extracting articles of manufacture from a trunk operating in a firstmode of motion and transferring the articles of manufacture forprocessing to a branch processing station operating at a second mode ofmotion and for returning processed articles of manufacture to the trunk.The transfer device includes a first portion having a first drive sourceoperating at the first mode of motion, and a second portion having asecond drive source operating at the second mode of motion. A conveyorassembly extends around the first portion and the second portion and issupported in an operative configuration for transporting articles ofmanufacture between the first portion and the second portion. Anaccumulating member separates the first portion from the second portionand is responsive to the first mode of motion of the conveyor assemblyon the first portion and is responsive to the second mode of motion onthe second portion.

[0015] Yet another aspect of the present invention is a branchprocessing station for a high speed manufacturing system for performingmanufacturing processes on articles of manufacture. The branchprocessing station includes a continuous feed indexer having a transportmechanism for conveying the articles of manufacture along the branchprocessing station in an indexed intermittent motion wherein at least aportion of the transport mechanism is arcuate and conveys the articlesof manufacture in an arcuate fashion. Each of the articles ofmanufacture is received by the transport mechanism at a singletangential point along the arcuate portion while the transport mechanismis in motion. At least one process module is mounted to the indexer forperforming the at least one process on the articles of manufacture.

[0016] Another aspect of the present invention is a process module formounting to a high speed manufacturing system to perform a manufacturingprocess on articles of manufacture wherein the articles are undercontrol of the manufacturing system. The process module includes achassis having a base and a processing mechanism mounted to an exteriorof the chassis for performing a process on the articles of manufacture.The chassis further includes an acquiring mechanism to place the articleof manufacture under control of the process module and to place theprocessing mechanism in an operative position with respect to thearticle of manufacture for performing the process thereon. A controlelement is also associated with the chassis wherein the control elementdirects the acquiring mechanism to gain control of the article ofmanufacture and directs the processing mechanism in a tasking sequenceof placing the processing mechanism in the operative position withrespect to the article of manufacture. The control element directsperformance of the process by the processing mechanism and disengagesthe processing mechanism from the article of manufacture to returncontrol of the article to the manufacturing system.

[0017] Another aspect of the present invention is a processing conveyorsystem for processing articles of manufacture. The conveyor systemincludes a transport conveyor for transporting the articles ofmanufacturing from a beginning of the system to an end of the system. Atleast one article segregator junction is intermediate the beginning andthe end and an article segregator is positioned at the articlesegregation junction for segregating the articles of manufacture fromthe transport conveyor. At least one article integrator junction ispositioned downstream from the article segregator junction and anarticle integrator is positioned at the article integrator junction forintegrating the articles of manufacture onto the transport conveyor. Anarticle processing conveyor is positioned between the articlesegregation junction and the article integration junction.

[0018] These and other advantages of the invention will be furtherunderstood and appreciated by those skilled in the art by reference tothe following written specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In the drawings:

[0020]FIG. 1 is a plan view of a modular high speed processing systemembodying the present invention shown configured for processing batterycans into completed batteries;

[0021]FIG. 2 is an exploded perspective view of a branch processingstation and transfer unit interposed between two trunk segments;

[0022]FIG. 3 is a perspective view of a branch processing station;

[0023]FIG. 4 is an elevational view of the drive end of a continuousfeed indexer;

[0024]FIG. 5 is an elevational view of the idler end of a continuousfeed indexer showing the tensioning mechanism;

[0025]FIG. 6 is a perspective view of a toothed segment of the endlesstransport belt from the continuous feed indexer;

[0026]FIG. 7 is a perspective view of a toothed segment of the endlesstransport belt with a battery can transport cleat engaged therewith;

[0027]FIG. 8 is a side elevational view of the cleat fastened to thebelt and showing magnets embedded therein for retaining the battery canto the cleat;

[0028]FIG. 9 is a plan view of a cleat fastened to the endless belt andshowing a battery can retained by the cleat;

[0029]FIG. 10 is a plan view of the drive end of the continuous feedindexer showing dead plates around portions of the drive pulley for thetransfer of battery cans to and from the continuous feed indexer;

[0030]FIG. 11 is an elevational cross-sectional view of the continuousfeed indexer taken along the line XI-XI in FIG. 10;

[0031]FIG. 12 is a side elevational view of the continuous feed indexershowing the battery cans after processing and illustrating the verticalrealignment of the battery cans prior to being extracted from thecontinuous feed indexer;

[0032]FIG. 13 is a plan view of the home sensor and slotted disk for thecontinuous feed indexer;

[0033]FIG. 14 is a perspective view of a transfer device fortransferring battery cans from the continuous motion trunk to theindexed motion continuous feed indexer;

[0034]FIG. 15 is an exploded view of the reciprocating element of thetransfer device;

[0035]FIG. 16 is a plan view of the transfer device;

[0036]FIG. 17 is an enlarged elevational view of one end of thereciprocating element mounted on its guide rail taken along the lineXVII-XVII of FIG. 16;

[0037]FIG. 18 is an elevational end view taken along the lineXVIII-XVIII of FIG. 16;

[0038]FIG. 19 is a side elevational view of the transfer device takenalong the line XIX-XIX of FIG. 16 showing the optical sensors forgenerating control signals to the control coordinator;

[0039]FIG. 20 is a side elevation and end elevation of the rail uponwhich the reciprocating element translates;

[0040]FIG. 21 is a cross-sectional view of one of the transfer devicedrive pulleys taken along the line XXI-XXI of FIG. 16;

[0041]FIG. 22 is a partial cross-sectional view of a fixed idler for thetransfer device taken along the line XXII-XXII of FIG. 16;

[0042]FIG. 23 is a plan view of battery can carrying cleats affixed tothe smooth surface of an endless toothed transport belt;

[0043]FIG. 24 is an elevational view of the battery can carrying cleatsaffixed to the transport belt;

[0044]FIG. 25 is a perspective view of a battery can carrying cleat forthe transfer device;

[0045]FIG. 26 is a perspective view of ends of two adjacent continuousmotion conveyors forming a portion of the trunk;

[0046]FIG. 27 is a plan view of a continuous motion conveyor;

[0047]FIG. 28 is an elevational view of a continuous motion conveyor;

[0048]FIG. 29 is a cross-sectional elevation view of the continuousmotion conveyor taken along the line XXIX-XXIX of FIG. 28;

[0049]FIG. 30 is a perspective view of a coupler mounted on a spindle;

[0050]FIG. 31 is a partial cross-sectional view of a couplerillustrating the dial attachment, and further illustrating dead platesupports, and dead plates;

[0051]FIG. 32 is a plan view of the coupler dial showing pockets definedaround a periphery of the dial;

[0052]FIG. 33 is an elevational view of one pocket of the coupler dialtaken along the line XXXIII-XXXIII of FIG. 32;

[0053]FIG. 34 illustrates the pulleys, idlers, and couplers associatedwith the conjunction of a branch processing station with the trunk;

[0054]FIG. 35 shows the continuous motion drive belt for powering theadjacent continuous motion conveyors, couplers, and one side of thetransfer device, and the indexing motion drive belt for powering thecontinuous feed indexer, couplers, and the indexing side of the transferdevice;

[0055]FIG. 36 is a plan view of a processing station, transfer deviceand adjacent continuous motion conveyors illustrating the path of travelof the battery cans therealong;

[0056]FIG. 37 shows the dead plate supports for the couplers, transferends of the continuous motion conveyor, transfer device, and continuousfeed indexer;

[0057]FIG. 38 is a perspective view of one 45 degree dead plate segment;

[0058]FIG. 39 is an elevational view of the dead plate segment shown inFIG. 38;

[0059]FIG. 40 is a bottom plan view of the dead plate segmentsillustrating the dowel receiving groove;

[0060]FIG. 41 is a partial cross-sectional view of the battery cantransfer from the continuous feed indexer to the adjacent coupler;

[0061]FIG. 42 is an elevation view of a first embodiment of a processmodule for mounting on a continuous feed indexer;

[0062]FIG. 43 is a side elevational view of a second embodiment of aprocess module mounted to a continuous feed indexer for extracting abattery can from the indexer for processing and return to the indexer;

[0063]FIG. 44 is an enlarged partial cross section of the battery canprocessing mechanism of FIG. 43;

[0064]FIG. 45 is a front elevational view taken through line XLV-XLV ofFIG. 44 showing the canted drive for spinning the battery can duringprocessing;

[0065]FIG. 46 is a top plan view taken along the line XLVI-XLVI of FIG.44 showing the battery can extraction mechanism disengaged from thebattery can;

[0066]FIG. 47 is a top plan view of the battery engaging mechanism ofFIG. 46 showing the mechanism having extracted the battery from a cleatand spinning the battery can for processing;

[0067]FIG. 48 is an exploded perspective view of a precision mount formounting the process modules to a continuous feed indexer;

[0068]FIG. 49 is a block diagram illustrating the control systemhardware architecture employed in the high speed manufacturing system ofthe present invention;

[0069]FIG. 50 is a block diagram illustrating the control coordinator ofthe distributed control system;

[0070]FIG. 51 is a block diagram illustrating the local process stationcontroller of the distributed control system;

[0071]FIG. 52 is a block diagram illustrating the process modulecontroller of the distributed control system;

[0072]FIG. 53 is a block diagram illustrating the continuous motionconveyor controller of the distributed control system;

[0073]FIG. 54 is an illustration of a broadcast protocol forcommunicating notices and reports in the distributed control systemaccording to a first embodiment;

[0074]FIG. 55 is an illustration of a process station-chain protocol forcommunicating notices and reports in the distributed control systemaccording to a second embodiment;

[0075]FIG. 56 is an illustration of a hybrid protocol for communicatingnotices and reports in the distributed control system according to athird embodiment;

[0076]FIG. 57 is an illustration of a centralized protocol with cellidentification for communication in the distributed control systemaccording to a fourth embodiment;

[0077]FIG. 58 is a block diagram illustrating operational modes of thecontrol coordinator and handling tasks associated therewith;

[0078]FIG. 59 is a block diagram illustrating operational modes of theprocess station controller and handling tasks associated therewith;

[0079]FIG. 60 is a block diagram illustrating a class hierarchy andmethods associated with each class;

[0080]FIG. 61 is a comparative graph illustrating manufacturing articlethroughput realizable as a function of the number of process modules andprocessing time;

[0081]FIG. 62 is a control interaction diagram illustrating the sequenceof communications between control agents during normal operation of thehigh speed manufacturing system;

[0082]FIG. 63 is a schematic diagram illustrating the processing ofarticles of manufacture on a four-up continuous feed indexer with fourprocess modules and an experimental process module;

[0083]FIG. 64 is a graph illustrating the index and dwell intermittentmotion of the continuous feed indexer;

[0084]FIG. 65 is a block diagram further illustrating the variousproximity sensors for monitoring the position of the transfer device;

[0085]FIG. 66 is a state diagram illustrating control of the continuousfeed indexer in response to the proximity sensors shown in FIG. 65; and

[0086]FIG. 67 is a graph illustrating the movement of the dancer as afunction of time.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0087] For purposes of description herein, the terms “upper,” “lower,”“right,” “left,” “rear,” “front,” “vertical,” “horizontal,” andderivatives thereof shall relate to the invention as oriented in FIG. 2,with reference to a viewer in front of the trunk, directly facing towardthe processing stations. However, it is to be understood that theinvention may assume various alternative orientations and stepsequences, except where expressly specified to the contrary. It is alsoto be understood that the specific parts, devices and processesillustrated in the attached drawings and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

[0088] The reference numeral 2 (FIG. 1) generally designates a modularhigh speed processing system embodying the present invention. Modularhigh speed processing system 2 is particularly adapted for creating aprocessing line for the manufacture and processing of articles ofmanufacture at a pre-selected manufacturing rate and where amanufacturer desires to track and monitor individual articles throughoutthe processing sequence. As discussed below, modular high speedprocessing system 2 is comprised of unique discrete functional elementswhich can be arranged in multiple configurations to create a processingsystem tailored to a manufacturer's needs. While the embodiment of themodular high speed processing system described herein is directed at themanufacture and processing of battery cells for consumer electronicappliances, it will be understood that the modules and functionalelements described are adaptable for the processing of a wide range ofother articles of manufacture.

[0089] As illustrated in FIGS. 1 and 2, modular high speed processingsystem 2 includes individual branch processing stations 6, 14, and 16interconnected by trunk 4 wherein processing stations 6, 14, and 16perform the desired processing of the articles to be manufacturedthereon and trunk 4 transports the articles between processing stations.The sequencing and monitoring of processing system 2 is accomplishedwith a control system having a control coordinator 610 whichcommunicates with individual process station controllers 614, 616, and618. Individual process station controllers 614, 616, and 618 providethe control interface for processing stations 6, 14, and 16respectively, the functioning of which is described more fully below.

[0090] The processing system 2 as illustrated in FIGS. 1 and 2 comprisesat least one branch processing station such as station 14 having aplurality of processing modules 12 located therealong for processing ofindividual articles of manufacture such as battery cans 34. As shown inFIG. 2, branch processing station 14 comprises a plurality of individualmodular elements to facilitate the transport and processing of thebattery cans 34 and is typical of other branch processing stations. Atransfer device such as device 8 b is located at one end of a continuousmotion conveyor 18, or between two ends of continuous motion conveyors18 and 20. Transfer device 8 b extracts battery cans 34 from continuousmotion conveyor 18 for delivery to branch processing station 14. Afterprocessing, the battery cans are extracted from branch processingstation 14 by transfer device 8 b and delivered to continuous motionconveyor 20 for transport to the next branch processing station such asstation 16.

[0091] The continuous motion conveyors 18 and 20 form trunk 4 forconveying the battery cans in a constant speed motion between individualprocessing stations 6, 14, and 16. A platform 28 b or a suitablesupporting frame is utilized to support and maintain the ends ofcontinuous motion conveyors 18 and 16, transfer device 8 b, and branchprocessing station 14 in a fixed operating relationship. Couplers 32 areutilized to hand off battery cans 34 between adjacent elements such asbetween continuous motion conveyor 18 and transfer device 8 b andbetween transfer device 8 b and branch processing station 14. Branchprocessing station 14 comprises a continuous feed indexer 15 whichtransports battery cans 34 in an indexed manner and process modules 12.The indexed motion of continuous feed indexer 15 transports battery cans34 in an alternating index-dwell sequence wherein process modules 12perform their scheduled process on battery cans 34 during the dwellportion of the transport of battery cans 34 about indexer 15. While thepreferred embodiment incorporates a trunk 4 operating at a continuousconstant speed motion and the branch processing stations 6, 14, and 16operating at an indexed intermittent motion, the speeds and modes ofmotion of the trunk and branch processing stations can be continuous,variable or intermittent with transfer device 8 transitioning betweenthe differing motions. While the trunk has a first mode of motion thatis continuous and the branch processing stations have a second mode ofmotion that is intermittent, it should be appreciated that the firstmode of motion may be intermittent and the second mode of motion may becontinuous.

[0092] According to processing system 2 as shown in FIG. 1, battery cans34 are introduced to branch processing station 6 by input module 22.Input module 22 takes battery cans 34 which are input thereto in a bulkrandom manner and orients cans 34 to a common upright orientation anddelivers the cans in an indexed manner to continuous feed indexer 7where the cans are transported for processing by process modules 10.

[0093] An experimental process module 36 can be located at any desiredposition throughout system 2 to conduct experimental processing in lieuof production processing to test and evaluate new methods and equipmentof processing. Because control coordinator 610 monitors each battery canposition during transport, the experimental processing can take place inconcert with standard production and the experimentally processedbattery cans can be identified and extracted for evaluation at theconclusion of the processing cycle.

[0094] After completion of processing by process modules 10, batterycans 34 are extracted from continuous feed indexer 7 and have theirmotion converted from indexed motion to continuous motion by transferdevice 8 a. Battery cans 34 are then transferred to continuous motionconveyor 18 where they are transported to a subsequent branch processingstation 14 for processing by process modules 12 and 24, and then tothird branch processing station 16 for further processing by processmodules 13. The number of process modules at each branch processingstation is determined by the time required for the individual processand providing sufficient quantity of process modules to maintain adesired production throughput. The manner of determining the number ofmodules is discussed in more detail below. Upon completion ofprocessing, battery cans 34 are removed from system 2 by extractionmodule 26 for testing, packaging, and delivery of the final product.

[0095] A more complete understanding of the components of high speedprocessing system 2 is gained from a detailed description of each of themodules comprising processing system 2.

Continuous Feed Indexer

[0096] With reference to FIGS. 3-5 a continuous feed indexer 15comprises a central frame 40 to which are affixed a drive assembly 49 atone end and an idler assembly 59 at an opposite end with a conveyorassembly extending therearound. In the preferred embodiment the conveyorassembly is an endless transport belt assembly 68 extending betweendrive assembly 49 and idler assembly 59. A process module support 80 ispositioned proximate to at least one side of continuous feed indexer 15and to which are attached one or more process module mounts 82, theconfiguration of which is discussed more fully below.

[0097] Referring to FIGS. 3 and 4, drive assembly 49 is fastened to oneend of frame 40. Drive assembly 49 comprises a drive frame 110 andsupports spindle assembly 108 in which is journaled a drive shaft 106.At a top end of drive shaft 106, a cogged drive sprocket 50 is attachedto shaft 106 to rotate in a horizontal plane. A home sensor 112comprising a slotted disk 114 affixed to an upper end of shaft 106 torotate therewith and an optical sensor 116 fixed to frame 40 is utilizedto align the transport belt assembly 68 on the continuous feed indexer15 in a manner more fully described below. A drive pulley 52 is affixedto a lower portion of shaft 106 below spindle assembly 108, and a servodrive motor 54 is affixed to the bottom of shaft 106 for providing therotational power to drive pulley 52 and sprocket 50.

[0098] Referring to FIGS. 3 and 5, idler assembly 59 and tensionerassembly 66 are located at the opposite end of frame 40. End plate 90 isfastened to the end of frame 40 opposite from drive assembly 49. Endplate 90 includes upper and lower bushings 87 and 89 extending intointernal channels 47 of frame 40. Idler assembly 59 includes an idlersupport 61 to which cogged idler sprocket 60 is affixed to rotate in ahorizontal plane. An end plate 62 extends around idler sprocket 60 andis spaced a fixed lateral distance from sprocket 60. The fixed distanceof end plate 62 from idler sprocket 60 is slightly more than theoutermost distance of the outer edge of a battery can as it traversesaround sprocket 60 such that battery cans 34, as they traverse aroundsprocket 60, are at least partially retained by track 63 in end plate62. A vertical idler end plate 84 is affixed to idler support 61 and hasalignment shafts 86 and 88 attached thereto. Shafts 86 and 88 extendhorizontally forward from plate 84 and are closely received in bushings87 and 89 respectively to permit the fore and aft adjustment of idlerassembly 59 with respect to frame 40 and drive assembly 49.

[0099] The fore and aft adjustment of idler assembly 59 is accomplishedby tensioner assembly 66 and provides the proper tensioning to transportbelt assembly 68 on continuous feed indexer 15. Tensioner assembly 66comprises a pivot attach bolt 100 affixed to an upper end of end plate90 at the idler end of frame 40. A tensioner arm 96 is pivotally affixedto an end of pivot attach bolt 100 and pivots about pivot pin 94 whichextends horizontally through tensioner arm 96 and bolt 100. A lowerportion of tensioner arm 96 has a nose 102 which bears against idler endplate 84 at a point coincident with the plane of centerline 104 oftransport belt assembly 68 and pulley 60. Adjustment bolt 92 extendsthrough an upper end of tensioner arm 96 and engages end plate 90. Acoil biasing spring 98 is sleeved over adjustment bolt 92 and bears onthe upper end of tensioner arm 96 and on end plate 90 to bias the upperend of tensioner arm 96 against adjustment bolt 92.

[0100] Referring now to FIGS. 6-9, transport belt assembly 68 comprisescontinuous belt 70 and a plurality of cleats 72. A chain could besubstituted for belt 70. Belt 70 is a continuous belt of a desiredlength to extend around drive sprocket 50 and idler sprocket 60 and hasa plurality of cogs or teeth 124 on an inner side 122 and a smooth outerside 120. Belt 70 is typically constructed of a metal reinforcedpolymer; however, alternative combinations of belts and cleats arepossible to achieve the purpose of assembly 68. Teeth 124 have holes 126extending vertically therethrough for the attachment of carriers tocarry the articles of manufacture. In the preferred embodiment carriersare cleats 72. The size and desired spacing of cleats 72 will determinewhich teeth 124 are designated to receive cleats 72.

[0101] Each of cleats 72 has an upper flange 128 and a lower flange 130which are vertically disposed one from the other by a vertical web 132.Vertical web 132 spaces flanges 128 and 130 to closely receive belt 70therebetween such that smooth surface 120 of belt 70 abuts vertical web132 of cleat 72. Flanges 128 and 130 each have a hole 145 extendingvertically therethrough which is vertically aligned with hole 126 inbelt teeth 124 when cleat 72 is abutted to belt 70. Cleat 72 is securedto belt 70 by inserting pin 146 through holes 126 and 145. Holes 126 and145 closely receive pin 146 thereby preventing the inadvertentdislodgment of pin 146. Belt 70 is compressed slightly to create aninterference fit of cleat 72 and pin 146 to belt 70. However, pin 146can be readily removed to facilitate the replacement of a damaged cleat72 on belt assembly 68 without requiring the removal of belt assembly 68from continuous feed indexer 15. Alternatively, teeth 124 can have a pinfixed therein to mate with holes 145 facilitating the installation andremoval of cleats 72 in a snap-in fashion. Flanges 128 and 130 also haveat a distal end thereof a groove 129 and 131 respectively. Grooves 129and 131 can receive therein a guide rail fixed along frame 40 tolaterally stabilize cleats 72 for counteracting the magnetic force whencans 34 are extracted, thereby maintaining cleats 72 in a desired trackaround continuous feed indexer 15.

[0102] Cleat 72 also has upper flange 134 extending forward from web 132and is coplanar with flange 128. Likewise, a lower flange 136 extendsforward from lower flange 130. Steel dowel pins 138 extend forward fromouter edges of flanges 134 and 136 forming recess 135 therebetween.Recess 135 receives therein one of the battery cans 34 for transportalong continuous feed indexer 15. Flanges 134 and 135 also have embeddedin a central portion thereof magnets 140 and 142 respectively forretaining a battery can 34 in recess 135. Alternatively, cleat 72 can beconstructed to retain an engaging portion of a standard sized adapterwhich, in turn, has a capture portion to hold a desired size batterycan. In this manner, the conveyor assembly can accommodate differentsize articles of manufacture by simply changing adapters.

[0103] Referring now to FIG. 11, a cleat backup rail 167 is attached toan upper slot 42 of frame 40 with bolt 172 engaging nut 170 which iscaptive in slot 42. Cleat backup rail 167 runs the length of frame 40and has upper and lower shoulders 169 for receiving flanges 128 and 130of cleat 72. Shoulders 169 maintain cleats 72 in a predefined verticalposition along indexer 15. Cleat backup rail 167 can also have a guiderail 168 which engages either or both grooves 129 and 131 of cleat 72 toalso provide lateral stability for cleat 72 to maintain cleat 72 in aclose lateral relationship with backup rail 167. Below backup rail 167,a support 158 is affixed to frame 40. Support 158 is attached to frame40 in the same manner as cleat backup rail 167, using nuts captive inslots 42 of frame 40 and bolting support 158 thereto. A bottom cellsupport rail 164 is affixed to an upper surface of support 158. Bottomcell support rail 164 has a shoulder 165 at an outer edge for receivingtherealong and supporting thereon the bottom of battery cans 34 as cans34 are conveyed along indexer 15. Bottom cell support 164 also has anupper surface substantially corresponding to support bottom flange 136of cleat 72. Side rail supports 160 are affixed to and located atregular intervals along support 158. Side rail supports 160 haveattached to an inner side thereof side rails 162 which have an innersurface 163 to guide the outer surface of battery cans 34. In thepreferred embodiment, each of side rail 162, bottom cell support rail164 and cleat backup rail 167 is formed from a self lubricating materialsuch as an oil impregnated nylon or similar material to minimize wearand facilitate the movement of belt assembly 68 around indexer 15.Alternatively, rails 164 and 167 and be formed from any low friction orwear resistant material.

[0104] Referring to FIG. 12, as the cans are processed on indexer 15,and returned to trunk 4, individual cans 34 may have been verticallyshifted with respect to the carrying cleat 72. Therefore, any cans 34that have become vertically shifted during processing are realigned withcleats 72 prior to extraction of cans 34 from indexer 15. For thispurpose, individual hold-down magnets 166 are embedded in the bottomcell support rail 164 at a plurality of locations along rail 164.Because belt assembly 68 indexes about indexer 15 in a motion-dwellmanner, cleats 72 pause at consistent predefined positions. Hold-downmagnets 166 are positioned at these locations. When cleats 72 stopduring the dwell portion of the belt assembly 68 motion about indexer15, battery cans 34 are directly above magnets 166. The magnetic fieldof magnets 166 is designed to be sufficient to pull an individual can 34down to contact the shoulder surface 165 of bottom cell support rail164.

[0105] Referring now to FIGS. 4 and 13, a home sensor 112 is mountedabove drive sprocket 50 of indexer 15 drive assembly 49. Home sensor 112comprises a slotted disk 114 which rotates in conjunction with drivesprocket 50. Slotted disk 114 has a plurality of radially oriented slots115 therearound spaced to correspond to the radial spacing of cleatsaround sprocket 50. Each of slots 115 has a leading edge 113 and atrailing edge 117. Whenever processing system 2 is restarted from anunknown condition, each element of system 2 is reset to a known ‘home’position. The home sensor 112 is utilized for this function by opticalsensor 116 sensing the passage of trailing edge 117 of one of slots 115in disk 114 thereby disrupting the signal condition of the opticalsignal generated by sensor 116. By sensing and adjusting the position ofslotted wheel 114, system 2 can reset indexer 15 to a known conditionwhere cleats 72 are moved to a predefined position about indexer 15.Alternatively, a commercially available rotary transducer could beutilized as a home sensor for the nominal alignment of transport belt68.

Transfer Device

[0106] Referring now to FIGS. 14 and 16 a transfer device 8 is shown fortransferring battery cans 34 from the continuous motion trunk conveyor 4to a processing station 14 for processing thereon and from processingstation 14 returning processed battery cans 34 to continuous motiontrunk conveyor 4. Additionally, transfer device 8 transitions the motionof the battery cans from the continuous motion of trunk 4 to the indexedmotion of continuous feed indexer 15. Transfer device 8 includes acontinuous motion drive sprocket 180 which is rotatingly driven by servomotor 288 and an indexed motion drive sprocket 182 in line withcontinuous motion drive sprocket 180. Drive sprockets 180 and 182 aretoothed or cogged sprockets which engage toothed transport belt assembly196. A carriage 184 comprising an input flying idler 188 and an outputflying idler 190 are laterally disposed one from the other by belttensioning bar 186 or alternatively pulled apart by a wire rope andpulley arrangement and is positioned midway between sprockets 180 and182. Belt tensioning bar 186 is oriented perpendicular to a lineconnecting the centers of sprockets 180 and 182 thereby configuringtransfer device 8 in a cruciform configuration. An endless transportbelt assembly 196 comprising an endless belt 198 and a plurality ofcleats 200 affixed to belt 198 for carrying battery cans 34 extendsaround the drive sprockets 180 and 182 and around flying idlers 188 and190. Belt tensioning bar 186 acts on the centerline of belt 198 toreduce loading forces applied to linear rail 174 and carriage block 175(FIG. 17). Fixed idlers 194 are positioned proximate to the intersectionof the two axes of the cruciform wherein belt assembly 196 is routedaround the inside of fixed idlers 194 thereby directing belt assembly196 to follow a perimeter of the cruciform.

[0107] Referring to FIGS. 23-25, transport belt assembly 196 comprises atoothed belt 198 to which are attached at regularly spaced intervals aplurality of cleats 200 for carrying battery cans 34 about the peripheryof transfer device 8. In the preferred embodiment, belt 198 issignificantly wider than belt 70 used on continuous feed indexer 15 andcleats 200 are fastened to belt 198 in a different manner than thecleats 72 of belt assembly 68. Cleat 200 has a vertical web 246 whichmaintains upper flange 250 and lower flange 252 in a vertically disposedrelationship. Flanges 250 and 252 extend horizontally from upper andlower ends of web 246 respectively. Each of flanges 250 and 252 havehardened steel dowel pins extending from the outer edges of the flangeto define a recess 255 therebetween for receiving a battery can 34 fortransport about transfer device 8. As in cleats 72, cleats 200 also haveupper and lower magnets 256 and 258 embedded in a central portion ofupper and lower flanges 250 and 252 respectively for attracting andretaining a battery can 34 within recess 255. A vertical rib 248protrudes from the back of web 246 and extends from the top of web 246to the bottom of web 246. Rib 248 is the only portion of cleat 200 whichabuts belt 198 thereby leaving a small clearance between the remainderof web 246 and belt 198. The clearance at the ends of cleat 200 allowsbelt assembly 196 to make an inside turn around fixed idlers 194. Cleats200 are centered on a tooth 244 of belt 198 and are adjacently spacedcorresponding to the spacing of cleats 72 on indexer belt assembly 68.In the preferred embodiment, cleats 200 are fastened to belt 198 withthreaded fasteners 260, with the threads of fasteners 260 engaging rib248 and web 246. The use of threaded fasteners permits the rapidreplacement of cleats 200 without necessitating the removal of beltassembly 196 from transfer device 8. However, alternative means forclamping cleats 200 to belt 198 are possible and within the scope ofbelt assembly 196.

[0108] Referring now to FIGS. 15, 17, 18 and 20 the dancer carriage 184comprises a linear rail 174 having base plates 173 attached to a bottomof rail 174 for mounting to a support base 172. Linear rail 174 is anelongate rail having an hourglass profile as shown in FIG. 20. A belttensioning bar 186 has an idler support 176 attached at each end thereofand forms an accumulating member. Idler support 176 at an input end ofcarriage 184 supports a rotatable input flying idler 188 and an endplate 189 at an outer end thereof. Similarly, an idler support 176 at anoutput end of carriage 184 supports a rotatable output flying idler 190and an end plate 191 at an outer end thereof. Idler supports are mountedto carriage blocks 175. Carriage blocks 175 have an internal linear,recirculating ball bearing for translating along rail 174 with minimalfriction. To obtain the proper tension of belt assembly 196, belttensioning bar 186 is provided with adjustable links 187 at each endthereof for increasing or decreasing the distance between flying idlers188 and 190. Each of flying idlers 188 and 190 has a recess 192 aboutits periphery to permit the clearance of heads of fasteners 260retaining cleats 200 to belt 198. End plates 189 and 191 are positionedat the end of flying idlers 188 and 190 and spaced from the idler'sperimeter to permit the passage of belt assembly 196 therearound whenbelt assembly is transporting battery cans 34. End plates 189 and 191are sufficiently close to idlers 188 and 190 to prevent centrifugalforce from disengaging battery cans 34 from cleats 200 as belt assembly196 traverses the perimeter of transfer device 8.

[0109]FIG. 21 illustrates indexed motion drive sprocket 182 in partialsection (continuous motion drive sprocket 180 being similarlyconstructed and configured). Drive sprocket 182 is toothed to engage theteeth 144 of belt assembly 196. Sprocket 182 has a recess 218 about thecentral part of its periphery to clear the heads of fasteners 260mounting cleats 200 to belt 198. Sprocket 182 is mounted to shaft 221with a compression type sleeve 216 to ensure that sprocket 182 iscentered and firmly secured to shaft 221. Any slippage of sprocket 182on shaft 221 will result in misalignment of processing system 2requiring shutting the system down to readjust the coordination betweenbattery can 34 carrying elements. Shaft 221 is support by and journaledin spindle assembly 220. Spindle assembly 220 is significantly widerthan shaft 221 to provide rigid support of shaft 221 in a verticalorientation. Shaft 221 extends from the bottom of spindle assembly 220and has a cogged pulley (not shown) attached thereon for drivingsprocket 182. A dead plate support 224 is attached to the top of spindleassembly 220 and has dowel pins 226 inserted in hole about itsperiphery. One or more dead plates 225 are attached to dead platesupport 224 and function to guide and retain battery cans 34 in cleats255 as they traverse about the periphery of drive sprocket 182.

[0110]FIG. 22 shows fixed idler 194 connected to shaft 234 which isjournaled in idler support 232. Idler support 232 has a mount base 236at a bottom portion thereof to facilitate mounting the fixed idler tosupport frame or platform 28. Since the fixed idlers 194 are utilized bybelt assembly 196 to make an inside turn about the periphery of transferdevice 8, cleat 255 and battery can 34 face the fixed idler. Each fixedidler 194 then has a recess about the central portion of its peripheryso that idler 194 does not interfere with cleats 255 or battery cans 34in a manner that would induce belt assembly 196 not to engage idler 194.The contact of belt assembly 196 on idler 194 guarantees that beltassembly 196 does not change length when one or more cleats 255 do notcarry a battery can 34.

[0111] Referring now to FIG. 19 transfer device 8 has associatedtherewith a plurality of sensor and switches to control the operation ofprocessing system 2. An input limit switch 201 and an output limitswitch 202 are mounted at the respective input and output ends of rail174. An end block 177 is affixed to the end of each idler support 176such that if transfer device 8 was driven to an overly input richcondition (dancer carriage 184 translated to the left with battery cans34 to be processed) or to an overly output rich condition (dancercarriage 184 translated to the right with processed battery cans 34),end block 177 would actuate the associated limit switch 201 or 202 whichwould cause system 2 to be shut down and require the realignment ofprocessing system 2 elements. The limit switches 201 and 202 are thelast resort shutdown for system 2 to prevent damage to processing system2. Input and output end of travel sensors are positioned to opticallysense the programmed limits of travel of dancer carriage 184, and todisable processing system 2 if the limits were to be breached. Thetransfer device 8 also has a home sensor to sense the proper resettingof carriage 184 to its home position when initializing processing system2. Finally, indexing enable sensor 206 and indexing disable sensor 212are positioned along rail 174 to sense the maximum desired operationaltravel of carriage 184 and to therefore, in turn, disable the indexingdrive when transfer device 8 becomes output rich and to enable theindexing drive when transfer device 8 becomes input rich.

Continuous Motion Conveyor

[0112] Referring to FIGS. 26-29, trunk 4 typically comprises one or morecontinuous motion conveyors 18 and 20 to transport the articles ofmanufacture such as battery cans 34 from one branch processing station16 to a subsequent branch processing station 16 and continuing until alldesired processing steps have been accomplished.

[0113] Each continuous motion conveyor such as conveyor 18 is similar inconstruction to that of continuous feed indexer 15. Continuous motionconveyor 18 comprises a central frame 270 from the same extruded slottedbeam as frame 40 of continuous feed indexer 15. Frame 270 has firstidler assembly 272 attached to one end of frame 270 and second idlerassembly 274 attached to an opposite end of frame 270. A first tensionerpulley assembly 276 is mounted to the top of frame 270 proximate tofirst idler assembly 272 and a mirror image second tensioner pulleyassembly 278 is mounted to the top of frame 270 proximate to secondidler assembly 274. A transport belt assembly 279 comprising endlesstoothed belt 292 and cleats 72 extends around continuous motion conveyor18 for transporting of battery cans 34 in one direction only. Transportbelt assembly 279 utilizes the same toothed belt construction as belt 70used in belt assembly 68, and also uses the same cleats 72 attached tobelt 292 in the same manner with a pin extending through rear flanges128 and 130 of cleat 72 and through individual teeth of the belt.

[0114] Each of idler assembly 272 and idler assembly 274 comprises asupport 283 to which spindle 284 is attached. Spindles 284 are mountedto a frame or platform 28 (FIG. 1) and support continuous motionconveyor 18 therebetween. Spindle 284 has a shaft 285 journaled at a topand bottom of spindle assembly 284 and further extends above and belowspindle assembly 284. A first cogged pulley 280 is affixed to the upperend of shaft 285 on first idler assembly 272 and a second cogged pulley282 is affixed to the upper end of shaft 285 on second idler assembly274.

[0115] Referring to FIG. 29, the continuous motion conveyor 18 is shownin cross section. First tensioner pulley assembly 276 is bolted to thetop of frame 270. Tensioner support 294 extends to the right of frame270 and horizontal tensioner pulley 296 depends therefrom. As shown inFIG. 29, transport belt assembly 279 returns to the idler assembly 274from the opposite end of conveyor 18 without carrying any battery cans34. Since the return portion of belt assembly 279 does not carry cans 34and as a result of its continuous motion does not experience vibrationsinduced by starting and stopping, belt assembly 279 does not requiresupport beyond tensioner idler pulley assemblies 276 and 278. The leftside of conveyor 18 is used to transport battery cans 34 from oneprocessing station to another and thus requires support similar to thesupport provided on both sides of continuous feed indexers such asindexer 15. A backup rail 302 is affixed to an upper portion of frame270 at upper slot 298 in frame 270. A captive nut 300 is retained inslot 298 for engagement by bolt 304 to secure cleat backup rail to frame270. Support block 306 is affixed to frame 270 at a lower slot in amanner similar to backup rail 302. A bottom cell support rail 308 isattached to the upper surface of support block 306. Cleat 72 of beltassembly 279 rides along an upper surface of support rail 308 whilebattery cans 34 ride along a shoulder 310 at an outer end of supportrail 310. A plurality of side rail supports 312 are attached alongsupport block 306 to support side rail 314. Side rail 314 is positionedto maintain battery cans 34 captive in cleats 72 as the battery cans areconveyed from one end of continuous motion conveyor to the other end. Asin continuous feed indexer 15, backup rail 302, bottom cell support rail308, and side rail 314 are fabricated from a self-lubricating materialsuch as oil impregnated nylon or other low friction or wear resistantmaterial.

Coupler

[0116] As illustrated in FIG. 2, a coupler is positioned intermediateadjacent ones of continuous motion conveyors 18 and 20, transfer devices8, and continuous feed indexers 7, 15, and 17. Each coupler 32 performsa transfer function between these adjacent elements. For example, onecoupler 32 will extract battery cans from the input side of transferdevice 8 and deliver them to the input side of continuous feed indexer 7for processing. After processing of cans 34 on continuous feed indexer7, a second coupler 32 extracts the processed cans 34 from the outputside of continuous feed indexer 7 and delivers them to the output sideof transfer device 8. Couplers 32 are similarly used to transfer cans 34between continuous motion conveyors 18 and transfer device 8. Couplers32 are the connecting links between the various transport and processingelements of system 2 permitting these elements to be combined in aninfinite number of arrangements while maintaining the capability of acontinuous and uninterrupted flow of articles of manufacture throughoutsystem 2.

[0117] Referring to FIGS. 30-32, a coupler 32 comprises a spindleassembly 320 having a mounting flange 322 extending outwardly therefromfor mounting to a frame or platform such as platform 28 (FIG. 1).Mounting flange 322 has a plurality of holes 324 therearound tofacilitate securing spindle assembly 320 to platform 28. A rotatableshaft 326 extends vertically through spindle assembly 320 and isjournaled in upper bearing 321 at an upper end of spindle assembly 320and in bearing 327 at a lower end of spindle assembly 320. Shaft 326extends below spindle assembly 320 and has one or two cogged pulleys 328mounted thereto. Shaft 326 also extends upwardly through spindleassembly 320 and has mounted thereto at its upper end a dial assembly330. Dial assembly 330 has a dial 332 which can be molded of aninjectable resin or machined from plastic metal or ceramic, and isshaped to minimize weight and rotational inertia.

[0118] As shown in FIGS. 32 and 33, dial assembly 330 is generallycircular and has a plurality of pockets 350 defined by a perimeter 351of dial 332. Each pocket 350 is shaped to receive a portion of a batterycan 34 and has an upper magnet 352 and a lower magnet 354 embeddedwithin the portion of dial perimeter 351 defining pocket 350 forcapturing and retaining battery can 34 therein.

[0119] Referring now to FIG. 31, a central web 333 of dial 332 iscaptured between washer plate 334 and hub 336 and is fastened to washerplate 334 and hub 336 by bolts 334. Dial assembly 330 is sleeved overshaft 326 as is a taper lock compression fitting 338 which is receivedby an inner diameter of washer plate 334 and hub 336. Taper lockcompression fitting 338 has an upper tapered insert 340 and a lowertapered insert 342 which are received between inner chamfered ring 346sleeved over shaft 326 and outer chamfered ring 348 bearing against theinner diameter of hub 336. A plurality of closely spaced bolts 339extend through compression fitting 338 in a manner to draw upper taperedinsert 340 and lower tapered insert 342 toward one another. As inserts340 and 342 are drawn together by bolts 339, the tapered surfaces ofinserts 340 and 342 compress inner ring 346 against shaft 326 and expandouter ring 348 against the inner diameter of hub 336 thereby securingdial assembly 330 to shaft 326.

[0120] A dead plate support 360 is affixed to a top of spindle assembly320. Dead plate support 360 has mounted thereon one or more dead plates356 and 358. As shown in the sectional view of FIG. 31, dead plate 356is secured to dead plate support 360 by a threaded fastener such as bolt364. Dead plates 356 and 358 are carefully positioned relative to dialassembly 330 so that battery cans 34 can rotate freely within deadplates 356 and 358 yet be sufficiently close to prevent battery cans 34from becoming dislodged or disengaged from pockets 350 in dial 332. Tothis end, dead plates such as dead plate 358 as shown in section has agroove 359 in a bottom surface in which is closely received dowel pins362 for precise radial positioning of dead plates 358 on dead platesupport 360. Dead plate 356 and 358 include upper and lower flanges tomaintain each can 34 in a desired vertical position with respect to dial332.

Drive Arrangement

[0121] Referring now to FIGS. 34 and 35, the upper pulley and drivesprocket arrangements are illustrated in FIG. 35. A continuous motiongroup 370 whose motion requires coordinated speed for proper interfaceand transfer of battery cans 34 in association with trunk 4 includes thefirst idler sprocket 280 of a receiving continuous motion conveyor 20,the continuous motion drive sprocket 180 of transfer device 8, and acoupler 32 to transfer cans 34 from sprocket 180 to sprocket 280.Likewise, a second coupler 32 is interposed between transfer devicecontinuous motion drive sprocket 180 and second idler sprocket 282 ofcontinuous motion conveyor 18. A second group of couplers and sprockets,indexed motion group 372, also requires a coordinated drive includes acoupler 32 for extracting battery cans 34 from indexed motion drivesprocket 182 of transfer device 8 and transferring cans 34 to the inputside of drive sprocket 50 of continuous feed indexer 15. A secondcoupler 32 extracts battery cans 34 from the output side of drivesprocket 50 and delivers cans 34 to the indexed motion drive sprocket182 of transfer device 8.

[0122] Referring now to FIG. 35, drive group 370 is powered by servomotor 288 from transfer device 8. In the preferred embodiment, adouble-sided cogged drive belt 378 engages drive pulley 374 of transferdevice 8 to provide the desired rotational motion to couplers 32 viatheir drive pulleys 328 and the rotational motion for continuous motioncogged pulleys 280 and 282 of continuous motion conveyors 20 and 18,respectively, via their respective idler pulleys 286 and 290. Propertension to belt 378 is provided by belt tensioner 376. Byinterconnecting idler pulley 290 of continuous motion conveyor 18 withthe idler pulley 286 of continuous motion conveyor 20, the speed oftrunk 4 is coordinated and remains substantially constant from one endof processing system 2 to the other end.

[0123] The desired rotational motion for the indexed motion group 372 isprovided by servo motor 54 which powers drive sprocket 50 and drivepulley 52 of continuous feed indexer 15. Drive pulley 52 isinterconnected to pulley 328 of couplers 32 and to indexed motion drivepulley 380 which in turn drives index motion drive sprocket 182 oftransfer device 8. In the preferred embodiment a doubled-sided coggedbelt 386 is also used in this group in conjunction with idler 384 andtensioner 382 for providing the proper tension to belt 386. However, adrive system of intermeshed gears could also be utilized to impart thedesired rotational motion to drive group 370 and indexed motion group372.

Operation

[0124]FIG. 36 illustrates the operation of process station 14 withrespect to the transportation of battery cans 34 removed from trunk 4for processing on process station 14 and returned to trunk 4. As shownin FIG. 1, trunk 4 generally comprises a plurality of continuous motionconveyors arranged in an end-to-end configuration such as conveyors 18and 20 with process stations positioned at ends of the individualcontinuous motion conveyors. Process station 14 as shown in FIG. 36 inrelative operating position with respect to trunk 4 is typical of theprocess station to trunk interface and illustrates the preferredembodiment with respect to the processing of battery cans 34. However,an infinite number of arrangements of components are possible.

[0125] Belt assemblies such as belt assembly 279 of continuous motionconveyors 18 and 20, belt assembly 196 of transfer device 8, and beltassembly 68 of continuous feed indexer 15 all progress around theirrespective frames in a clockwise direction. All couplers 32 rotate in acounterclockwise direction. However, the respective directions of travelcan be reversed with couplers 32 rotating in a direction opposite thebelts.

[0126] Transport belt assembly 279 of continuous motion conveyor 18transports battery cans 34 along directional arrow 411. Each battery can34 is retained by a cleat 72 of belt assembly 279. As cans 34 progressaround idler sprocket 282 they are transferred to first input coupler390 and proceed therearound in captive fashion in a counterclockwisedirection as indicated by directional arrow 412. First input coupler 390is also adjacent continuous motion drive sprocket 180 of transfer device8 and cans 34 are transferred from coupler 390 to individual cleats 200of belt assembly 196 on transfer device 8. The transfer point of cans 34occurs at the tangent point coupler 390 and sprockets 282 and 180. Allcan 34 transfers occur in like manner throughout system 2.

[0127] As previously discussed, carriage 184 with input flying idler 188and output flying idler 190 at its respective ends divides transferdevice 8 into a continuous motion side adjacent to trunk 4 and anindexed motion side adjacent to continuous feed indexer 15. Cans 34progress along transfer device 8 in a continuous motion manner accordingto directional arrows 413 and 414. As cans 34 progress around inputflying idler 188, their motion along directional arrows 415 and 416 istransformed into an indexed motion. The indexed motion comprisesalternating periods of belt assembly 196 translation having a speedgreater than the continuous motion speed of trunk 4 and a periods ofdwell in which the motion of cans 34 is stopped.

[0128] In the preferred embodiment, the average speed of the indexedmotion is slightly greater than the continuous motion speed of trunk 4.The translation component along the indexed side of transfer device 8 isdetermined by the number of cans simultaneously processed on continuousfeed indexer 15. Thus, if six battery cans 34 are simultaneouslyprocessed as shown by processing station 14 in FIG. 1, the translationcomponent of indexed motion comprises positionally incrementing beltassembly 196 a distance equivalent to six times the distance betweenadjacent cleats 200. The dwell component of the indexed motioncorresponds to the time required to accomplish the required processingof cans 34 by process modules 12 on continuous feed indexer 15. Thus,the continuous motion of belt assembly 196 along directional arrows 413and 414 will cause the leftward translation of dancer carriage 184 to aninput rich position 398 of transfer device 8.

[0129] Concurrently, the indexed motion along directional arrows 415 and416 causes incremental rightward translations of dancer carriage 184toward an output rich position 400. The continuous motion alongdirectional arrows 413 and 414 during the dwell component of the indexedmotion returns carriage 184 toward input rich position 398. Since theaverage speed of the indexed motion along directional arrows 415 and 416is slightly faster than the continuous motion speed of trunk 4, eachcycle of indexed motion-dwell causes dancer carriage 184 to slowlymigrate to output rich position 400 over a period of indexed motioncycles. Upon dancer carriage 184 reaching output rich position 400continuous feed indexer 15 is temporarily disabled by process stationcontroller 616 thereby allowing the continuous motion of drive sprocket180 to reset transfer device 8 to input rich position 398. Upon transferdevice 8 being reset to input rich position 398, continuous feed indexer15 is again enabled to resume indexed processing of cans 34. Theoscillating motion of dancer carriage 184 and its resetting from outputrich position 400 to input rich position 398 is graphically illustratedin FIG. 67 as a time function and is additionally discussed below withrespect to the control system.

[0130] As cans 34 progress along directional arrow 416 and aroundindexed motion drive sprocket 182, each can 34 is captured by secondinput coupler 392 and progresses in a counterclockwise direction 417 andis then in turn captured by cleats 72 of belt assembly 68 on continuousfeed indexer 15. Cans 34 progress along continuous feed indexer 15 asshown by directional arrow 418 and are processed by one or more processmodules (not shown) during the dwell period of the index dwell motion ofbelt assembly 68. After processing, cans 34 proceed around idlersprocket 60 and along directional arrow 419 in the same manner ofindexed motion for return to trunk 4. Upon reaching drive sprocket 50,processed cans 34 are handed off to first output coupler 394 and proceedtherearound in a counterclockwise direction as indicated by directionalarrow 420.

[0131] First output coupler 394 transfers cans 34 to individual cleats200 of belt assembly 196 on transfer device 8 on the right or outputside of transfer device 8. Cans 34 continue to proceed in an indexedmotion-dwell manner along directional arrows 421 and 422 to outputflying idler 190. After rounding output flying idler 190, cans 34transition to continuous motion and proceed according to directionalarrows 423 and 424. Upon reaching continuous motion drive sprocket 180,second output coupler 396 captures individual cans 34 and transportsthem in a counterclockwise manner according to directional arrow 425whereupon cans 34 are handed off to individual cleats 72 at drivesprocket 280 of continuous motion conveyor 20. Cans 34 then proceed in acontinuous motion manner along directional arrow 426 to be transportedto one or more additional process stations. All battery can 34 transfersare accomplished at the tangential points of dials 332 and interfacingbelt assemblies.

[0132] Referring now to FIGS. 37-41, a plurality of dead plates 428 arearranged about the periphery of those areas where cans 34 aretransported in an arcuate manner. Dead plates 428 function to retaincans 34 within the carrying cleats 72 or 200 and within pockets 350 ofcouplers 32. In this manner, dead plates 428 serve to prevent cans 34from disengaging from the magnets as a result of the centrifugal forceimparted to cans 34 around couplers 32 or end sprockets of continuousmotion conveyors 18 and 20, transfer device 8, or continuous feedindexer 15.

[0133] Secondarily, dead plates 428 also function to ensure that cans 34are properly handed off from a cleat 72 or 200 to a coupler 32 or thereverse thereof. To properly position dead plates 428 along the path ofcans 34, dead plate supports such as dead plate support 360 are mountedto an upper end of spindle assemblies such as spindle assembly 32 inFIG. 30. Each fixed drive and idler sprocket and coupler involved withthe transfer of battery cans 34 have at least one dead plate and a deadplate support associated therewith.

[0134] The dead plate supports in the preferred embodiment, have fourbasic configurations. D-shaped dead plate support 430 is mounted to thetop of the spindle assembly associated with the drive and idlersprockets of continuous motion conveyors 18 and 20 and of continuousfeed indexer 15. Dead plate support 430 has an arcuate end and a linearend, wherein the linear end is oriented toward the central frame such asframe 40 of continuous feed indexer 15 and the arcuate end is coaxialwith the sprocket shaft and is oriented away from the outer end of thesprocket. The remaining dead plate supports can be circular such as deadplate support 436, can have one arcuate cut-out in its periphery such asdead plate support 432 or two arcuate cut-outs in its periphery such asdead plate support 434 wherein the cut-outs are separated by 90 degrees.The arcuate cut-outs permit the nesting of dead plate supports for theproper mounting of dead plates 428.

[0135] The differently configured dead plate supports 432-436 alsofacilitate the ability to position individual elements such ascontinuous motion conveyors 18 and 20, transfer device 8, and continuousfeed indexer 15 at any desired angular relationship one to the other.Dead plate supports 430-436 are coplanar to provide a continuous surfaceupon which to mount dead plates 428. Each of dead plate supports 430-436have a plurality of dowel pin holes 438 at regularly spaced predefinedintervals near the perimeter of the dead plate supports. Dowel pins arepartially received within holes 438 such that a portion of the dowel pinextends about a top surface of the dead plate support for engagementwith a groove, such as groove 444 in FIG. 40, in a bottom surface ofdead plate 438. A dead plate 428 can bridge adjacent nested dead plates430-436.

[0136] A typical dead plate is illustrated in FIGS. 38-40 as dead plate440. Dead plate 440 corresponds to one of the dead plates positionedbetween drive sprocket 50 of continuous feed indexer 15 and first outputcoupler 394 as shown in FIG. 41. Dead plate 440 has a bottom surface 442which defines a groove 444 having a width to closely receive thelocating dowel pins protruding from dead plate supports 430-436. Deadplate 440 also has at least one threaded hole 446 in a bottom portion orother clamping mechanism to facilitate the securing of dead plate 440 toits corresponding dead plate support. The bottom portion of dead plate440 has a shelf 448 which corresponds to the bottom of a battery can 34as can 34 is transported around processing system 2. Similarly, a topportion of dead plate 440 has an upper lip 450 which is verticallydisposed above shelf 448. Shelf 448 and lip 450 are vertically separatedby web 454 and in combination define a channel 452 for the passage of atleast a portion of a vertically oriented battery can 34 therealong.

[0137] Web 454 is either solid or can have a window 456 defined at oneend thereof. Window 456 may be rectilinear or, as shown in FIGS. 38 and39 have a tongue 458 which further defines at one end of window 456 andin combination with an upper portion of web 454, a slot 460 and incombination with a bottom portion of web 454, a slot 462. The purpose ofwindows 456 are to permit the passage therethrough of dial 330 ofcouplers 32 or of cleats 72 or 200 at the point of battery can 34 handoff from a coupler dial 330 to a cleat 72 or 200 or from a cleat 72 or200 to a coupler dial 330. Slots 460 and 462 permit the unrestrictedpassage of the upper and lower flanges of cleats 72 and 200therethrough. The size and configuration of window 456 and slots 460 and462 correspond to the width of dials 330 and to the vertical dimensionsof cleats 72 or 200 such that during the operation of processing system2, there is no portion of dead plate 440 which interferes with thepassage of a dial 330 or cleats 72 or 200 as they pass through window456 and slots 460 and 462.

[0138] Referring to FIG. 41, transport belt assembly 68 is illustratedat drive sprocket 50 of continuous feed indexer 15 wherein battery cans34 are handed off to first output coupler 394 after processing oncontinuous feed indexer 15. As cleats 72 carry battery cans 34 towarddrive sprocket 50, straight dead plate 466 ensures that battery cans 34are retained in recesses 135 of cleats 72. As belt assembly 68 engagesdrive sprocket 50 and begins to turn around an outer periphery of drivesprocket 50, cans 34 encounter a curved dead plate 468 having a web 470whose inside surface is maintained at a constant radius from the centerof drive sprocket 50. Dead plate 468 has a rectilinear window 472through a central portion thereof to permit first output coupler 394 torotate therein.

[0139] Coupler 394 is synchronized with belt assembly 68 such that asbelt assembly 68 progresses around drive sprocket 50, pockets 350defined by the outer perimeter of coupler 394 engage and receive aportion of a battery can 34. A second dead plate, dead plate 440 isabutted to the opposite end of dead plate 468 and is oriented toradially conform to the outer periphery of coupler 394 such that web 454and tongue 458 engage the portion of battery can 34 within recess 135 ofcleat 72 and opposite from pocket 350 of coupler 394. At the point oftransition from dead plate 468 to dead plate 440, battery can 34 iscaptured by both coupler 394 and cleat 72. As coupler 394 rotates in acounterclockwise direction according to directional arrow 420, web 454and tongue 458 engage the portion of battery can 34 received by cleat72. Web 454 and tongue 458 operate to disengage battery can 34 fromcleat 72 and to maintain battery can 34 in an engaged relationship inpocket 350 of coupler 394.

[0140] All transferring of battery cans 34 from a carrying cleat 72 or200 to a coupler 32 and the transferring of a battery can 34 from acoupler 32 to a cleat 72 or 200 are accomplished in a similar mannerthroughout processing system 2. The transfer of battery cans 34 usesalternately oriented dead plates to guide a battery can 34 about aperiphery of a carrying element from which the can 34 is to bedischarged, engaging a synchronized carrying recess in a receivingelement, and transferring carriage of the battery can 34 to thereceiving element with the oppositely oriented dead plate.

Process Modules

[0141] As shown in FIG. 1, a branch processing station such as station 6has one or more process modules 10 mounted to a continuous feed indexer7 to acquire control of a battery can 34 during the dwell period of theindexed motion, perform at least one process on battery can 34, and thenreturn control of battery can 34 to indexer 7. A second branchprocessing station 14 has an alternately configured process module 12mounted to continuous feed indexer 15 for performing a secondmanufacturing process on battery cans 34. One configuration of processmodule 12 as mounted to continuous feed indexer 15 is shown in FIG. 42.Process module 12 includes a base 482 which is received in processmodule mount 82 attached to process module support 80. A process modulecontroller 620 is associated with each chassis 480 and can be mountedinteriorly or exteriorly of chassis 480. Controller 620 is incommunication with process station controller 614 and controlcoordinator 610 and includes signal inputs for receiving signals fromcontroller 614 and coordinator 610. The synchronized control of theoperation of process module 12 by process module controller 620, processstation controller 614 and control coordinator 610 is discussed ingreater detail below. Process module controller 620 controls theoperation of application head 498 in a synchronized manner with thedwell portion of the index motion-dwell of continuous feed indexer 15.

[0142] Process module 12 has an internal frame 484 to which is mountedservo motor 486. Servo motor 486 in turn is coupled to verticallyoriented rotatable threaded shaft 488 with coupler 487. A pair of guideshafts 490 are supported by and extend upwardly from frame 484 and flankthe upper portion threaded shaft 488 in a parallel manner. A carriage492 has a pair of sleeves 494 in which guide shafts 490 are receivedsuch that carriage 492 is vertically slidable along guide shafts 490.Carriage 492 further has a threaded element 496 attached thereto andengages rotatable threaded shaft 488. As servo motor 486 is operated,carriage 492 is vertically translated along guide shafts 490 through therotation of threaded shaft 488 in threaded element 496. Carriage 492 canbe translated upwardly by rotating servo motor 486 in one direction andlowered by rotating servo motor 486 in an opposite direction. A frontend 497 of carriage 492 extends through chassis 480 proximate tocontinuous feed indexer 15. Application head 498 is mounted to carriageend 497.

[0143] Process module mount 82 positionally locates process module 12along the longitudinal axis of continuous feed indexer 15 such that whena battery can 34 and cleat 72 are at the dwell portion of the indexedmotion-dwell sequence, application head 498 is directly aligned withbattery can 34 in a cleat 72. As battery can 34 dwells on continuousfeed indexer 15, process module controller 620 activates servo motor 486to rotate in a direction to lower carriage 492 and bring applicationhead 498 into an operational processing position. Application head 498is then activated to perform its desired process which when completed,is vertically raised from its engagement with can 34 by reversing thedirection of servo motor 486 and raising carriage 492 on guide shafts490. Upon disengagement of application head 498, cleats 72 and batterycans 34 retained therein are indexed along continuous feed indexer 15.

[0144] Referring now to FIG. 43 a second type of process module, processmodule 10 has a chassis 502 to which is mounted a process modulecontroller 620 which in turn communicates with process stationcontroller 614 of branch process station 14 and control coordinator 610in a similar manner as process module 12. A process module controller620 is associated with each chassis 502 and can be mounted interiorly orexteriorly of chassis 502. Chassis 502 includes a base 503 which isreceived in process module mount 82 on support 80 of continuous feedindexer 7. Process module 10 has a fixed application head 504 mounted toa top 506 of chassis 502. Process module 10 differs from process module12 in that process module 10 captures can 34 and disengages can 34 fromcleat 72 to position can 34 in a processing relationship with fixed head504.

[0145] A horizontally translatable carriage 508 has an upper arm 519 anda lower arm 521 extending out of the front of process module 10 asprocess module 10 faces continuous feed indexer 7. Carriage 508 hasupper guide sleeves 26 sleeved over upper guide rails 24 and also haslower guide sleeves 527 sleeved over lower guide rails 525 in such amanner as to permit a horizontal translation of carriage 508 along rails526 and 525 in a precise, controlled manner. An actuator 510 isinteriorly attached to the front of chassis 502 and has a connecting rod512 extending rearwardly therefrom which is further connected tocarriage 508. Process module controller 620 generates signals toactivate actuator 510 to initiate operation of process module 10 duringthe dwell periods of the indexed motion-dwell of cans 34 and cleat 72about continuous feed indexer 7. When an actuation signal is received byactuator 510, horizontal motion is imparted to connecting rod 512thereby translating carriage 508 to the left as shown in FIG. 43. Uponcompletion of the processing by fixed application head 504, a secondsignal is sent to actuator 510 to impart an opposite horizontal movementof carriage 508 to disengage battery can 34 from process module 10.

[0146] As shown in FIGS. 44-47, the horizontal movement of carriage 508in process module 10 results in a corresponding horizontal movement ofupper and lower arms 519 and 521, respectively. Upper arm 519 has a pairof upper idlers 520 depending therefrom and rotatable thereon. Likewise,lower arm 521 has a pair of lower idlers 522 rotatably mounted thereonsuch that idlers 520 and 522 are in a vertically opposed relationshipand are disposed vertically one set from the other by a distance whichis slightly greater than the vertical height of cleat 72. Arms 519 and521 are vertically positioned such that cleat 72 passes between idlers520 and 522 in an unobstructed manner when cleats 72 and battery cans 34are translated along continuous feed indexer 7. Process module 10 alsoincludes a vertically oriented servo motor 516 which, through coupler515, is drivingly connected to spin drive 518. Spin drive 518 isslightly canted with respect to the vertical.

[0147] As cleat 72 and battery can 34 dwell along continuous feedindexer 7, process module controller initiates the actuation of carriage508 which translates to the left. As carriage 508 and arms 519 and 521translate, idlers 520 and 522 contact battery can 34 and disengage can34 from cleat 72. Can 34 nestles between laterally adjacent idlers 520and laterally adjacent idlers 522. Idlers 520 and 522 translatesufficiently to bring can 34 into contact with driving rib 517 of spindrive 518 as shown in FIG. 47. When can 34 is fully engaged with idlers520 and 522 and with drive rib 517 of spin drive 518, can 34 isdisengaged from cleat 72; however, can 34 has not been sufficientlydisplaced to be removed from the magnetic field which normally retainscan 34 in cleat 72. As battery can 34 contacts drive rib 517, spin drive518 imparts a spinning motion to can 34, and as a result of spin drive518 being canted off vertical, a slight downward force is imparted tocan 34 to maintain the bottom of can 34 in contact with bottom support523. Bottom support 523 has a single ball bearing (not shown) upon whichthe bottom of can 34 rests to facilitate the desired spinning of can 34while an internal coating is applied by fixed application head 504. Uponthe internal coating being applied to can 34, process module controller620 initiates voice coil actuator 510 to translate carriage 508 to theright and thereby disengage idlers 520 and 522 from can 34. Upondisengagement from can 34, the magnetic field of cleat 72 again attractsand captures can 34 within recess 135. Upon recapturing of can 34 inrecess 135, cleats 72 and cans 34 are indexed along continuous feedindexer 7 and the process is repeated with a subsequent can 34.

[0148] Process modules 10 and 12 as described above are illustrative ofrepresentative process modules and their corresponding operation withrespect to and in conjunction with continuous feed indexers 7 and 15.Those skilled in the art will understand that variations and otherconfigurations of process modules are possible for processing of othervaried articles of manufacture and for performing alternative processeson battery cans during the manufacture of dry cell batteries.

Process Module Mounts

[0149] Referring now to FIG. 48, a process module support 80 is shownwith a plurality of regularly spaced process module mounts 82 mountedthereto in relationship to indexer belt assembly 68. The lateral spacingof mounts 82 along continuous feed indexers corresponds to the number ofcans to be simultaneously processed and the programmed sequence of dwellperiods of belt assembly 68 to ensure that all battery cans 34 areprocessed. Process module mount 82 includes a mount platform 40 which issecured in slots 538 of support 80. Platform 540 has a planar uppersurface for receiving base 503 of a process module such as processmodule 10. Platform 540 has attached to one end thereof a retainer 542for receiving a front edge 531 of process module base 503 and platform40 has at an opposite end thereof quick release fastener 544 which isengagable in slot 532 at a rear of process module base 503. Processmodule mount 82 functions to precisely locate process modules such asprocess module 10 with respect to its corresponding continuous feedindexer. Process module 10 and its attached application head can bepositionally precalibrated off-line from the continuous feed indexersuch that when process module 10 is mounted on mount 82 the applicationhead associated therewith is repeatedly positioned with respect tobattery cans 34 carried by belt assembly 68. Retainer 542 of processmodule mount 82 includes both lateral and longitudinal locating featuresthereby rendering like calibrated process modules interchangeable. Quickrelease fastener 544 facilitates the rapid removal and installation ofprocess modules requiring replacement to minimize the downtimeassociated with a malfunctioning processing system 2.

Control System Hardware

[0150] The high speed manufacturing system 2 of the present inventionemploys a flexible and versatile distributed control system formonitoring and controlling the operation of the high speed manufacturingsystem. The distributed control system provides the functions necessaryto control the high speed manufacturing system including control of theoperation of the continuous motion conveyor, continuous feed indexers,transfer devices, as well as controlling the individual process modulesassociated with each branch processing station. In addition tocontrolling the various components of the high speed manufacturingsystem, the control system controls the routing of articles ofmanufacture throughout the high speed manufacturing system, monitors themanufacturing processes, tracks each article, and logs the history ofeach article on the manufacturing line, and is further capable ofrouting experimental articles to experimental process modules andtracking and logging the history of the experimental articles as well.The control system allows for experimental processing, qualificationruns and other process testing to occur without taking the manufacturingline out of a normal manufacturing production operation.

[0151] Referring to FIG. 49, the control system 600 for the high speedmanufacturing system is generally shown made up of a distributed networkof controllers for controlling the operation of the high speedmanufacturing system. According to the embodiment shown and describedherein, the distributed control system 600 includes a main controlcoordinator 610, three local process station controllers 614, 616, and618, and a designated number of process module controllers 620A-620L,each associated with a process module. The control system 600 provides areal-time operating system and has a communication bus platform providedvia ethernet communication bus 612 and bus 622 to connect thecontrollers in a distributed control network. Communication bus 612 mayinclude an ethernet 10Base-T bus connected to the main controlcoordinator 610 and each of local process station controllers 614, 616,and 618 and the continuous motion conveyor (CMC) controller 624. Each ofthe process module controllers 620A-620L are connected via communicationbus 622, to their designated local process station controllers 614, 616,and 618. Communication bus 622 may comprise individual communicationlines which include an ethernet communication link such as an ethernet10Base-T bus.

[0152] Each local process station controller is generally responsiblefor control and monitoring of the events taking place on one branchprocessing station of the manufacturing system. More particularly, eachlocal process station controller communicates with, including providescontrol signals to and receives data information from, one or moredesignated process control modules, the continuous feed indexer, and theassociated transfer device, all of which are preferably located on onebranch processing station. Accordingly, the first process stationcontroller 614 communicates with four designated process modulecontrollers 620A-620D, continuous feed indexer 7, and its associatedtransfer device 8, all of which are present on the first branchprocessing station. The second process station controller 616communicates with six designated process module controllers 620E-620J,continuous feed indexer 15, and its associated transfer device 8, alllocated on the second branch processing station. Finally, the thirdprocess station controller 618 communicates with two designated processmodule controllers 620K and 620L, as well as continuous feed indexer 17,and its associated transfer device 8, all located on the third branchprocessing station. While one process station controller is preferablydedicated to each branch processing station, it should be appreciatedthat more than one process station controller could be assigned to agiven branch processing station, and one process station controllercould be dedicated to serve more than one branch processing station.

[0153] The local process station controllers 614-618 are responsible forcommunicating with the process module controllers that are designatedthereto. The process station controllers 614-618 are also responsiblefor controlling the associated continuous feed indexers, includingcontrol of their timing and speed for the index and dwell intermittentmotion. In addition, the continuous feed indexer transmits informationto the corresponding process station controller to indicate when thecontinuous feed indexer has completed an index or dwell operation. Thetransfer device 8 transmits return data information back to thecorresponding process station controller regarding its operation.

[0154] In addition, the control system 600 further includes a continuousmotion conveyor (CMC) controller 624 which is also connected incommunication with the ethernet communication bus 612. The CMCcontroller 624 is a separate distributed controller that is dedicated tocontrolling the operation of the continuous motion conveyor(s) of thetrunk. The CMC controller 624 receives control signals, such as speedcontrol signals, from the control coordinator 610 and provides returndata information regarding the operation of the continuous motionconveyor. Accordingly, the communication bus 612 allows the controlcoordinator 610, process station controllers 614-618, and CMC controller624 to communicate with one another on one common distributed network.

[0155] The distributed control system 600 has communication links forallowing remote access to the ethernet communication bus 612 and controlcoordinator 610. It should be appreciated that communication bus 612 canbe wire or wireless. Remote access is achieved by way of a human machineinterface (HMI) 626 which may include a stand-alone computer connectedto the control coordinator 610. The human machine interface 626 allowsan operator to input command signals to the control system 600, as wellas retrieve data information from the control system 600. In addition, aremote material information system (MIS) 628 is provided incommunication with the ethernet communication bus 612. The materialinformation system may include a remotely located computer connectedthrough a communication line to the communication bus 612 to access thecontrol system 600. For example, the material information system mayinclude a long-distance communication link linking the communication bus612 of control system 600 to a remotely located computer to allow remoteaccess for inputting control signals and/or retrieving data informationfrom control system 600. Either the human machine interface 626 ormaterial information system 628 may be used to program the controlsystem 600, including such operations as downloading designatedsoftware, modifying control parameters, performing experimentation, aswell as handling other operations. In addition, the human machineinterface 626 and material information system 628 also allow for theretrieval of the process manufacturing information that is monitored andlogged by the control system 600. This may include retrieval of normalprocessing information, experimental processing information, articletracking information, and any other data acquired from the variouscontrollers and sensors of the control system 600.

[0156] The main control coordinator 610 is a programmable processorbased controller that coordinates and monitors the overall operation ofthe high speed manufacturing system. The main control coordinator 610distributes control signals to the process station controllers 614-618and CMC controller 624 via communication bus 612. Control signalsbroadcast from control coordinator 610 may include article noticemessages to notify the various process station controllers 614-618 ofoncoming articles of manufacture, as well as other information. The maincontrol coordinator 610 also receives and records information receivedfrom the process station controllers 614-618 and CMC controller 624.Messages received by the control coordinator 610 may include work reportmessages received from each process station controller which detail thework completed on each article of manufacture, preferably following eachprocess operation performed by the process modules.

[0157] Referring to FIG. 50, the hardware configuration for one exampleof the main control coordinator 610 is shown therein. The controlcoordinator 610 includes a central processing unit (CPU) 634, aninput/output port 636, flash memory 638, random access memory (RAM) 640,a network hub 642, contactors and relays 644, and a disconnect switch646. It should be appreciated and understand that various other standardcontroller components may be present in the control coordinator 610 orthe other controllers that are shown and described herein in connectionwith the control system 600. The central processing unit 634 may includea commercially available microprocessor, one example of which mayinclude Model No. MVME 2304, made available from Motorola. The randomaccess memory 640 and flash memory 638 are available to store programsoftware to perform designated process control functions as well asother operating system programs, and also to store data informationcollected with the control system 600. The network hub 642 includes atleast two 10 Base-T ethernet ports and allows communication via theethernet communication bus 612. The contactors and relays 644 may beutilized to perform an emergency stop of the manufacturing system, whiledisconnect switch 646 provides a means to turn off the power supply tothe control coordinator 610, which will also shutdown the control system600. It should be appreciated that the various components of the controlcoordinator 610 may be assembled together on one or more boards andarranged on a VME rack.

[0158] Additionally, the control coordinator 610 is further shown incommunication with a safety circuit 630 that links the controlcoordinator 610 to each of the process station controllers 614-618 andthe CMC controller 624. The safety circuit 630 provides a separatehard-wired connection that may be utilized to disconnect the controlsystem 600 power outputs when necessary, such as during an emergencycondition. A standard power supply 632 is also provided to the controlcoordinator 610, and may include 480 volts AC, which is preferablytransformed to a usable DC voltage of 24 volts DC or other suitablevoltage level.

[0159] The local process station controllers 614, 616, and 618 areprovided as local controllers to the branch processing stations and eachprocess station controller is designated to control the operationsassociated with one branch processing station of the manufacturingsystem, including control of the continuous feed indexer, its transferdevice, and the designated process modules, all of which are associatedwith one branch processing station. Accordingly, process stationcontroller 614 serves as a local controller to control the processingassociated with the first continuous feed indexer 7, transfer device 8,and process module controllers 620A-620D. The second process stationcontroller 616 controls the processing performed on the secondcontinuous feed indexer 15, its transfer device 8, and process modulecontrollers 620E-620J. The third process station controller 618 controlsthe processing associated with the third continuous feed indexer 17, itstransfer device 8, and process module controllers 620I and 620L. Inaddition, each process station controller receives data information,such as work progress reports, from its designated process modulecontrollers, transfer device and continuous feed indexer.

[0160] One example of a hardware configuration for the local processstation controller 614 is shown in FIG. 51. The process stationcontroller 614 hardware includes a distributed input/output gateway 648,a central processing unit (CPU) 650, flash memory 652, random accessmemory (RAM) 654, and a continuous feed indexer (CFI) servo control 656.In addition, the process station controller 614 has a network hub 858,contactors and relays 660 and a disconnect switch 662. The centralprocessing unit 650 may include a commercially available microprocessor,one example of which may include Model No. MVME 2023, made availablefrom Motorola. The flash memory 652 and RAM 654 allow for storing ofprogrammed software and data storage. The CFI servo control 656 providesan amplified servo control signal to the CFI's servo motor to controloperation of the continuous feed indexer. Network hub 658 includes atleast one ethernet port and allows for networked communicationconnections to bus 612, as well as communication connections to bus 622.The contactors and relays 660 allow for shutdown of the system during anemergency condition, while disconnect switch 662 allows for powerdisconnect from the process station controller 614 to thereby shutdownthe control system 600. The safety circuit 630 is shown connected to theprocess station controller 614 to provide a hard-wired connection thatmay be used to shutdown the control system 600 in case of an emergencyshutdown condition. A standard power supply 632 is also provided to theprocess station controller 614, and may include 480 volts AC, which ispreferably transformed to a usable DC voltage of 24 volts DC or othersuitable voltage level.

[0161] The process station controller 614 is further shown havingconnections to the continuous feed indexer via lines 664, 666, and 668.The CFI servo cabling line 664 allows for servo cabling to thecontinuous feed indexer to transmit drive signals to drive the servomotor associated with the continuous feed indexer. CFI DistributedI/O+24 V DC line 666 provides two-way communication, such as sensor andactuation signals, and power to the continuous feed indexer. CFI SafetyI/O line 668 provides a hard-wired safety circuit connection to thecontinuous feed indexer to shutdown the system in case of an emergencyshutdown condition. The process station controller 614 is further shownin communication with process module controllers via communication bus622. It should be evident that the other local process stationcontrollers 616 and 618 may be configured identical or similar tocontroller 614 as described above. Each local process station controlleris preferably delegated the responsibility for initiating the processsteps performed by the process modules associated therewith, as well ascontrolling the motion of the corresponding continuous feed indexer.

[0162] Each of the process module controllers 620A-620L are provided forcontrolling and performing the physical processes that are to beperformed by the associated process modules. For a battery manufacturingprocess application, such physical processes may include inputting cellson the continuous feed indexer, outputting cells off the continuous feedindexer, applying sealant to the battery can, inserting separators,inserting KOH, inserting anode gel, inserting collectors, crimping andclosing cells, and disposing of defective cells. It should beappreciated that the process module controllers are preferably softwaredriven and are programmed such that each process module controllerdrives one or more servo controlled motors to perform one or moredesignated processing operations.

[0163] One example of a process module controller 620 is shown in FIG.52, which is representative of the hardware configured for any ofprocess module controllers 620A-620L. The process module controller 620includes a central processing unit (CPU) 670, flash memory 672, randomaccess memory (RAM) 674, a servo controller 678, and a Base-T ethernetport 676. The central processing unit 670 may include a commerciallyavailable microprocessor, examples of which may include Model No.Pentium, made available from Intel Corporation, and Model No. Power PC604E made available from Motorola. Flash memory 672 and RAM 674 storedesignated program software and data information, while the servocontroller 678 generates servo control signals to drive one or moreactuators or motors, each of which is configured to perform a designatedprocessing operation in conjunction with the process module associatedtherewith. The Base-T ethernet port 676 allows communication with thecorresponding process station controller via the ethernet connection bus622. In addition, solid state relays 680 and a disconnect switch 682 areprovided on the process module controller 620 to allow for shutdown ofthe system. The process module controller 620 is connected incommunication with the corresponding process station controller to whichit is assigned by way of the ethernet communication bus 622, as well asthe safety circuit 688 which is a hard-wired line that allows foremergency shutdown of the system. The process module controller 620further communicates with sensors and actuators on line 684 to receivesensed data and initiate actuation of certain devices. Further, theprocess module controller 620 communicates via the servo controller 678with the designated motors associated with the process module.

[0164] The continuous motion conveyor controller 624 is shown in FIG. 53according to one example. Continuous motion conveyor controller 624includes a distributed input/output gateway 690, a central processingunit (CPU) 692, flash memory 694, random access memory (RAM) 696, and aCMCC servo control 698. The central processing unit 692 may include acommercially available microprocessor, one example of which may includeModel No. MVME 2023, made available from Motorola. Flash memory 694 andRAM 696 are available to store designated software programs as well asdata information. The CMCC servo control 698 provides servo controlsignals to control the actuation and speed of the drive motor 288 whichdrives the continuous motion conveyor 18. In addition, contactors andrelays 700 and a disconnect switch 702 are provided on the continuousmotion conveyor controller 624 to allow for shutdown of the systemduring an emergency shutdown condition.

[0165] The continuous motion conveyor controller 624 communicates withthe ethernet communication bus 612 as well as the hard-wired safetycircuit 630. In addition, the continuous motion conveyor controller 624has three lines 704, 706, and 708 connected to the continuous motionconveyor. Included is a CMCC servo cabling line 704 which allows servocontrol signals to be transmitted to the drive motor 288 associated withthe continuous motion conveyor 18. CMCC Distributed I/O+24 V DC line 706allows for two-way communication of sensor and actuator signals, as wellas power signals to the continuous motion conveyor. CMCC Safety I/O line708 provides a safety circuit connection to the continuous motionconveyor to allow for shutdown of the continuous motion conveyor duringan emergency shutdown condition.

[0166] It should be appreciated that the process module controllers620A-620L are controlled by software defined process module agents as isexplained herein. According to one embodiment, the process module agentsmay be included with and processed by the local process stationcontroller designated to controlling the associated branch processingstation on which the corresponding process module operates. According toa second embodiment, the process module agents may be programmed intoand processed by the individual process module controllers 620A-620Lassociated with the corresponding process module. In any event, theprocess module agent for controlling a specified process operation canbe distributed amongst the available controllers by storing andprocessing the agents software in either the local process modulecontroller associated with a particular process module or the processstation controller designated to that process module.

Control System Operation

[0167] The distributed control system 600 is software-based andpreferably uses an object-oriented software operating control system.According to one example, C++ object oriented programming may beemployed. The use of object-oriented software programming for thecontrol system 600 facilitates maintenance and reuse of the high speedmanufacturing system. The object-oriented software identifies thephysical and conceptual objects of the system and represents suchobjects as software agents. In addition, responsibilities, attributes,and services are assigned to principle classes. The control software isresponsible for checking and configuring the control system, initiatingoperation of the system and monitoring the status of the system,transporting articles of manufacture to and between process stations byway of the continuous motion conveyor, transfer device, and thecontinuous feed indexers, and managing the global conveyor system tomaximize article throughput and minimize transfer device-limit failures.In addition, the control system 600 notifies the process stations aboutthe status of oncoming articles, actuates the process stations accordingto the programmed work specifications, the article status, and theconveyor status, and records information about the processing of eacharticle of manufacture. Further, the control software effects shutdownof the control system when required, handles subsystem failures eitherby restoring the subsystem, replacing it, or shutting down the overallsystem, and resuming operation after either controlled or uncontrolledshutdowns, and provides an operating interface that supports the systemoperation and any problem diagnosis/resolution.

[0168] The physical objects of the system to which the control softwareis assigned agents include the control coordinator, the processstations, the process modules, the continuous motion conveyor, thecontinuous feed indexers, and the safety system. For each of theseobjects, which are controlled and/or monitored by the control software,object agents are defined to encapsulate their associated data andbehavior and their responsibilities are specifically allocated.According to one embodiment, the main control coordinator agent isallocated the responsibilities of checking and configuring the system,initiating system operation and monitoring system status, managing theglobal conveyor system to maximize article throughput and minimizetransfer device-limit values, notifying process stations about thestatus of oncoming articles, recording information about the processingof each article, effecting control system shutdown when required,handling subsystem failures either by restoring the subsystem, replacingit, or shutting down the overall system, and resuming operation aftereither controlled or uncontrolled shutdown. Some of theseresponsibilities involve checking, configuring, starting, interrogating,adjusting, and stopping subsystems such as the continuous feed indexers,continuous motion conveyor, and process stations. The main controlcoordinator agent delegates these responsibilities to the subsystemscontrolling agents that are associated with the continuous feedindexers, continuous motion conveyor, and processing station agents.Accordingly, the control coordinator 610 is responsible for thesupervisory control of the entire control system.

[0169] The control system 600 also includes a process station agentcorresponding to each physical process station on the high speedmanufacturing system. The process station agent is responsible forinstructing the corresponding process station to process articles ofmanufacture according to their work specification and status. There mayexist separate process station agents assigned to initiate each step ofthe manufacturing process carried out by a corresponding process module.For the battery manufacturing application, there may be separate processstation agents for initiating actuation of the inputting of cells,outputting cells, applying sealant, inserting separators, inserting KOH,inserting anode gel, inserting collectors, crimping and closing cells,and disposing of defective cells, as well as other operations.

[0170] The control system 600 further includes a process module agentcorresponding to each physical process module on the high speedmanufacturing system. The process module agent is responsible forcontrolling a designated process module to implement the specificindividual steps to perform the designated operation dedicated to thatparticular process module. The process module agent may be viewed as asoftware routine which instructs the process module to perform aspecified function according to the programmed routine. The processmodule agent further monitors the operation of the corresponding processmodule and sends monitored data in a work report to the process stationagent assigned thereto.

[0171] The main control coordinator agent interacts with each of theprocess station agents, and each of the process station agents interactswith each of the process module agents that are assigned thereto. Duringnormal manufacturing operation, the main control coordinator agent sendsarticle notice messages to the process station agents to notify theprocess station agents of the oncoming articles of manufacture. Aprocess station normally will not process the article of manufactureunless the process station agent which controls a particular processmodule has received an article notice message indicating that it shoulddo so and the continuous feed indexer has returned a report that it isin proper position. In response, the process station agent notifies thedesignated process module agent to initiate its programmed processoperation. Once the process module has completed its intended operation,the process module agent issues a work report message which is sent tothe process station agent. The process station agent then broadcasts thework report message to other process stations as well as to the controlcoordinator 610. The control coordinator 610 preferably monitors andrecords each work report message for each article of manufacture. Thework report messages issued by the process station agents may includeinformation describing the results of processing individual articles ofmanufacture, and may indicate whether the processing operation wassuccessful or not, may contain test results or other measurements, mayreport experimental processing information, and may include cellprocessing history data. These work report messages are sent to thecontrol coordinator, in support of its notification and record-keepingresponsibilities.

[0172] To communicate article notice messages and work report messages,the control system 600 of the present invention preferably uses aprotocol for communicating such information. Referring to FIG. 54, oneembodiment of a protocol that could be employed is shown and isidentified as a broadcast protocol 710 in which the process station 614agent broadcasts work report messages, as shown by dashed lines 712, tothe other process stations 616 and 618 agents as well as to the controlcoordinator 610 agent. A process station agent receiving a work reportmessage 712 examines the information to determine whether to process thearticle of manufacture that it refers to. The process station agent willgenerally process the article of manufacture if the work report message712 was issued by the process station agent controlling the processstation that precedes its own and if the article was processedsuccessfully. The control coordinator 610 agent initiates processing ofan article by broadcasting a dummy work report message 713 for itself,and simply records the work report messages 712 that it receives. Theadvantage of the broadcast protocol 710 is that activating ordeactivating a process station does not entail opening or closing ofnetwork connections.

[0173] Referring to FIG. 55, a second embodiment of a protocol referredto as the process station-chain protocol 716 is shown in which eachprocessing station determines whether an article of manufacture shouldbe processed further or rejected, and the process station agent sends anarticle notice message 714 directly to the appropriate process stationor disposal station, without the intervention of the control coordinator610. In doing so, the process station agents send copies of their workreport messages 712 to the control coordinator 610 agent for recording.By distributing responsibility for article-routing, the processstation-chain protocol 716 reduces the workload of the controlcoordinator 610 and reduces network traffic.

[0174] A third embodiment of a protocol is shown in FIG. 56 and isreferred to as the hybrid protocol 718 in which each process stationagent, such as process station 614 agent, sends its work report message712 for an article of manufacture to a local control coordinator proxy815. The local control coordinator proxy 815 determines which processstation should process the article of manufacture next and issues anarticle notice message 714 to the corresponding process station 616agent. In addition, the real control coordinator 610 issues an itinerarymessage 715 to each process station. The control coordinator proxy 615does not have to communicate with the real control coordinator 610throughout each article of manufacture, although the real coordinator610 informs the control coordinator proxy 615 of changes in theitinerary 715 for articles of manufacture. Thus, the hybrid protocol 718reduces the workload on the real coordinator 610 but at the same timeremoves knowledge of the line configuration from the process stationagents.

[0175] A fourth embodiment of a protocol is shown in FIG. 57 and isreferred to as the centralized protocol 719, which may or may not havearticle identification. According to the centralized protocol 719embodiment, each process station agent sends work report messages 712 tothe control coordinator 610. The control coordinator 610 examines thework report messages 712 to determine which process stations shouldhandle the corresponding articles of manufacture next, and then directsappropriate article notice messages 714 to the process station agentsassociated with those process stations. The control coordinator 610 alsorecords the work report messages 712 that are received.

[0176] In addition, an article identification scheme may be used in thecentralized protocol 719 for tracking articles of manufacture on themanufacturing system line by assigning to each article a sequence numbercorresponding to its position in the article stream, and to use thisnumber as an article identifier throughout the article's processing.Accordingly, a process station agent can identify arriving articles bykeeping a count of the transport cleats that have passed the processstation and adding the transport cleat offset to the count. Of course,this scheme requires that the order of articles on the line bepreserved, or any reordering of the articles be accounted for. As longas the reordering is deterministic, it can be accommodated by using twonumbers to track an article; namely, a sequence number (SN) and anarticle identifier (ID). These numbers are included in the articlenotice and work report messages. The control coordinator 610 assignseach article an article identification number upon its entry to themanufacturing system and this identification does not change during thearticle's processing, even if any reordering occurs. Any reorderingwould be accounted for by the control coordinator 610 and tracked asnecessary to account for the position of each article of manufacture.

[0177] For each continuous feed indexer on the manufacturing system,there preferably exists a continuous feed indexer agent which isresponsible for controlling the continuous feed indexer and itsassociated transfer device. The continuous feed indexer agent alsointeracts with the control coordinator 610 when the system isconfigured, started, or stopped, when a failure occurs, and when thecontrol coordinator 610 requests its status. In addition, the continuousfeed indexer agent monitors the condition of the continuous feed indexerand informs the control coordinator 610 of malfunctions, supports thecontrol coordinator's responsibility to manage the global conveyorsystem, and synchronizes the operation of the continuous feed indexerand associated process stations by interacting with the process stationagents.

[0178] A continuous motion conveyor agent is also provided forcontrolling the continuous motion conveyor. The continuous motionconveyor agent is responsible for interacting with the controlcoordinator 610 when the system is configured, started, or stopped, whena failure occurs, and when the control coordinator 610 requests itsstatus. In addition, the continuous motion conveyor agent monitors thehealth of the continuous motion conveyor and informs the controlcoordinator 610 of any malfunctions, and supports the controlcoordinator's responsibility to manage the global conveyor system.

[0179] With the control coordinator agent and process station agentsbeing physically distributed, remote proxies 615, such as shown in FIG.56, may be employed. A remote proxy is a local stand-in for a remoteserver and provides a server interface in place of the real controller.The remote proxy 615 may be used to encapsulate the details of networkcommunication and to make distribution of agents transparent to othercontrollers. It should be appreciated that each networked controller mayinclude a remote proxy that is representative of another controller withwhich that controller is to communicate. This allows for interactionbetween controller agents as though they were residing on the sameprocessing unit, even though the controllers are distributed.Alternately, it should be understood that communication between thedistributed controllers could be achieved using message queues which arewell-known in the art. It should also be appreciated that the softwareagents may run on one or more processing units with little configurationrequired.

[0180] Referring to FIG. 58, the primary operations of the controlcoordinator 610 agent are shown with interaction to other agents. Theprimary operations include startup 722, normal production mode 724,failure handling 726, and shutdown 728. During the startup operation722, the control coordinator 610 agent receives a startup command fromthe human machine interface 626 and, in response, configures andinitializes the various agents and data stores. This includesinitializing the system data bases with information on the physicallayout of the system and article itinerary. The control coordinator 610agent is also responsible for initiating each of the continuous motionconveyor controller 624, the continuous feed indexer 7, and the processstation controllers 614-618 to configure themselves through theconfiguration store based on the physical layout of the system.

[0181] Once the startup operation 722 is complete, the controlcoordinator 610 agent may begin the normal production mode operation 724to execute the processing operations for manufacturing articles ofmanufacture. During normal production mode 724, the control coordinator610 coordinates the manufacture processing operation which includesnotifying each process station controller of the presence,identification, and status of articles of manufacture that areapproaching the branch processing station corresponding to that processstation controller, as well as recording the results of processing eacharticle of manufacture. The control coordinator 610 also communicateswith the continuous motion conveyor controller 624, as well as thecontinuous feed indexer 7, preferably via the corresponding processstation controller.

[0182] With the failure handling operation 726, a safety monitor 720monitors the various controllers and reports any problems to the controlcoordinator 610. The control coordinator 610 can evaluate and attempt tocorrect or adjust manufacture operations when a failure has occurred,and may initiate shutdown of the system if necessary. The human machineinterface 626 may initiate a shutdown operation 728 in which the controlcoordinator 610 instructs the controllers to undergo a softwareshutdown. With a software shutdown operation 712, the control systemstores the position, identification, and processing information for eacharticle of manufacture on the manufacturing system so that processing ofthese articles may continue where it left off when the system is startedback up. This allows for continued manufacture of partially processedarticles, which reduces article waste and shutdown time.

[0183] Turning to FIG. 59, the primary operations of any of the processstation controller 614, 616 or 618 are shown interacting with variousdevices. During the startup operation 722, the process stationcontroller is instructed by the control coordinator 610 to initiatestartup. The process station controller can configure itself through theconfiguration source 730. In addition, the process station controllerpreferably configures each of the process module controllers 620 and thecontinuous feed indexer associated with the corresponding branchprocessing station.

[0184] During normal production operation 724, the process stationcontroller receives article notice messages from the control coordinator610, and further receives a CFI indexing status message from thecontinuous feed indexer 7. If the CFI position status message indicatesthat the continuous feed indexer 7 has indexed to the proper positionfor the next processing step, the process station controller instructseach process module 620 for which an article notice message was receivedto execute its processing operation. Upon completing its processingoperation, each process module 620 sends a return message to its processstation controller to inform of its processing status for that article.The process station controller in turn transmits a work report messageto the control coordinator 610 for recording. In addition, the processstation further instructs the continuous feed indexer 7 to move in anindex and dwell intermittent motion, preferably when instructed to do soby the control coordinator 610.

[0185] During the handle failure operation 726, the process stationcontroller interacts with the control coordinator 610, as well as theprocess modules and continuous feed indexer associated therewith. Thecycle stop shutdown operation 728 likewise interacts with the controlcoordinator 610, process module controllers, and continuous feed indexer7. Further, a diagnostics operation 734 is available with the processstation controller in which a diagnostic tool 732 interacts with theprocess station controller to perform diagnostic functions.

[0186] Referring to FIG. 60, a controller class hierarchy is illustratedwith a controller class 736 and four subclasses which include thecontinuous feed indexer class 738, the continuous motion conveyor class740, the process station class 742, and the process module class 743.The controller class 736 has assigned thereto primary methods whichinclude configure, cycle stop, status and get status, make ready, handlesafety shutdown, resume, start, and suspend. Each of the subclasses 738,740, 742, and 743 contain additional methods, and each subclass furtherinherits all the methods of the controller class 736 as represented byinheritance 744. In addition to the inherited methods, the continuousfeed indexer class 738 includes added primary methods such as thederegister station method, the station ready method, and the registerstation method. The continuous motion conveyor class 740 includes addedprimary methods such as the change speed method to change the continuousmotion conveyor's speed, and the conveyor speed get speed method toacquire the conveyor's speed. The process station class 742 includes twoadditional primary methods, namely, the actuate method and handlearticle notice method. The process module class 743 includes methods forperforming designated process functions.

[0187] The high speed manufacturing system of the present invention isdesigned and controlled to perform high speed manufacture processing ofarticles in a manner that is flexible in that system components aremodular, easily replaceable, and reconfigurable with the distributedcontrol system. Additionally, the manufacturing system is configured toallow expedient experimental processing of articles simultaneous to thenormal manufacturing process. To achieve experimental processing, themanufacturing system platform was developed with a specified set ofchoices for the number of identical process modules that are employed oneach branch processing station. To realize increased processingcapability on each branch processing station, the number up (N), whichis the number of process module operated in parallel for the sameprocessing operation, may be increased. This allows a larger number ofarticles to be processed on a single branch processing station for thoseprocesses that require more time to be performed than other processes.

[0188] According to one embodiment, the high speed manufacturing systemrestricted the number up (N) based on the following equation:N=2^(x)3^(y), where x=0 through 5, and y=0 or 1. Alternative embodimentscan restrict N to other values such as: N=2^(x)3^(y), where x=0 through4, and y=0 through 2. Based on the aforementioned equation, the numberup N for each branch processing station may be selected from thefollowing possible set of values: 1, 2, 3, 4, 6, 8, 12, 16, 24, 32, 48and 96. As long as the number up N for each branch processing station isselected from the available set of values, experimental processesperformed on articles of manufacture can also be conducted during anormal manufacturing operation and within a reasonable period of time.According to the particular example of the manufacturing system as setforth in FIG. 1, the first branch processing station employs a number upN equal to four, while the second and third branch processing stationsemploy a number up N equal to six and two, respectively. In order to runan experimental process for 1,000 articles with an experimentalprocessing module while the manufacturing system 2 is still performingnormal processing at a processing rate of 700 articles per minute, themanufacturing system would take approximately 13.33 hours. This isbecause manufacturing system is capable of processing one experimentalarticle for every twelve articles since, from the prime factorization,the factors of N=4 are 2*2, the factors of N=6 are 2*3, and the factorsof N=2 are 2. Since the lowest common factor therefore is 2*3*2=12, oneof every twelve articles may be experimental for the above example.

[0189] With particular reference to FIG. 61, examples are provided forthe number of process stations that are required as a function ofprocess time and article throughput (e.g., articles per minute), fortwo-third cycles provided that 67% of the cycle time is used for processoperations. Process example 746 illustrates that a large number ofprocess modules are required for a process execution time of 2.000seconds. Process examples 748, 750 and 752 illustrate that a reducednumber of process modules are required for process execution timeperiods of 0.500 seconds, 0.267 seconds, and 0.100 seconds,respectively. Process example 754 shows that a fast process executiontime period of 0.050 seconds requires even fewer process modules.Accordingly, the number up N required for a particular branch processingstation increases with the more time consuming processes.

[0190] The operation of the distributed control system 600 forcontrolling the high speed manufacturing system 2 of the presentinvention will now be described as follows. Prior to performingprocessing operations, the control system 600 will undergo an initialstartup operation in which the control coordinator 610 initiatesconfiguration of the various controllers and controlled devicesincluding the continuous feed indexer, the process stations, and theprocess module controllers. Once configured, each controller notifiesthe control coordinator 610 that it is ready for operation. The controlcoordinator 610 then requests alignment of the transfer devices 8 totheir predetermined home positions so that the control coordinator 610can account for the position and identification of each article ofmanufacture as it is conveyed and processed by the manufacturing system.The control system 600 is now ready for normal processing operation.

[0191] With reference to FIG. 62, the normal processing operation of thedistributed control system 600 is illustrated therein. During the normalmanufacturing operation, the control coordinator 610 sends an articlenotice message 756 to the process station controllers, such as processstation controller 614 which is shown. The process station controller614 also receives an actuate (cleats) message 758 from the continuousfeed indexer which indicates that the continuous feed indexer 7 hascompleted its index motion to the next processing position. When inproper position, the continuous feed indexer's transport cleats and thearticles carried thereon are aligned with process modules that are toperform the next processing operation. Once the process stationcontroller 614 received both the article notice message 756 and theactuate message 758, it sends actuate messages 760 and 762 to eachcorresponding process module controller such as process modulecontrollers 620A and 620B. Actuate messages 760 and 762 instruct thereceiving process module controllers 620A and 620B, respectively, toexecute the process operation for its associated process module.

[0192] Upon completing its process operation, each process modulecontroller 620 sends a return module report 764 and 766 to thecorresponding process station controller 614 informing it of thecompleted status. The process station controller 614 in turn transmitswork report messages 765 and 767 back to the control coordinator 610which contains the work progress information for each article ofmanufacture. The control coordinator 610 is thereby able to track andlog the history of each and every article of manufacture that isprocessed on the manufacturing system. In addition, each process modulecontroller 620 also transmits module clear messages 768 and 770 to thecorresponding process station controller 614 indicating that the processmodule has returned the article to the continuous feed indexer and isclear of the article that was previously processed. The process stationcontroller 614 further issues a station ready message 772 to thecontinuous feed indexer 7 to enable the continuous feed indexer 7 toexecute its index motion.

[0193] The normal processing operation is repeated for each article tobe processed. The high speed manufacturing system 2 can be shutdown witha normal shutdown operation, a failure shutdown or a safety shutdown. Anormal shutdown operation is executed with the control coordinator 610broadcasting a cycle stop message to each of the process stationcontroller, the continuous feed indexers, and the continuous motionconveyor, which instructs the devices to stop normal operation at theend of a cycle so that the normal operation can be restarted where itleft off without skipping any articles. A handle failure shutdownlikewise includes the control coordinator 610 broadcasting a cycle stopmessage to each of the process station controllers, continuous feedindexers, and the continuous motion conveyor to stop normal operation atthe end of a cycle, such that a restart is possible. However, the handlefailure shutdown is done in response to a handle failure signal. Thehandle safety shutdown involves a safety monitor, such as a transferdevice limit switch or door open detector, notifying the controlcoordinator 610 of a problem. In response, the control coordinator 610sends shutdown messages to each of the process station controllers,continuous feed indexers, and the continuous motion conveyor to shutdownthe system immediately.

[0194] Referring to FIG. 63, the operation of the first continuous feedindexer 7 is illustrated with line movement increments equal to thenumber up N=4 in which a series of articles 34 are conveyed in indexedintermittent motion to present the articles in position for processingby four normal process modules 10. The process modules 10 aresuccessively spaced apart from each other by a distance of N+1 articles.As such, for the N=4 example shown, process modules 10 are spaced fivearticles apart from the next process module. During normal processingoperation, each process module 10 performs its designated processoperation on every fourth article.

[0195] The high speed manufacturing system of the present inventionfurther allows for experimental processing of articles to be performedat the same time as normal processing is performed. This can be achievedby employing an experimental process module 36 as shown in parallel withone of the normal process modules 10. To perform experimentalprocessing, the experimental process module 36 is instructed to performprocessing on one article in place of one of the normal process modules.By spacing the normal process modules at N+1 articles, the experimentalmay be easily employed. It should also be understood that how often theexperimental process module 36 can be used may depend on the number ofexperimental processes performed and the common denominator of N foreach branch processing station as explained herein.

[0196] As mentioned above, each of the continuous feed indexers move inan indexed intermittent motion to provide a dwell period during whichprocessing occurs and an index period during which the continuous feedindexer moves. The indexed intermittent movement of the continuous feedindexer is illustrated in FIG. 64 as a function of velocity and time.During the index period 774, the continuous feed indexer is initiallyramped up in speed, levels off, and then is ramped down in speed untilthe proper dwell position is reached. During the dwell period 776, thecontinuous feed indexer remains put while process operations are allowedto occur. The intermittent indexing motion of the continuous feedindexer is repeated throughout normal operation.

[0197] Referring to FIG. 65, the seven proximity sensors are shownpositioned along the travel path of the transfer device 8 for monitoringthe transfer device's travel. The home position sensor 208 senses apredetermined home position of the transfer device 8 which allows thecontrol system 600 to begin the normal operation of the high speedmanufacturing system 2 in a known position. The CFI index enableposition sensor 206 and CFI index disable sensor 212 provide positionsensing that defines the normal travel limits of the transfer device 8upon which a transfer device reset occurs. More particularly, the CFIindex disable sensor 212 senses that the transfer device 8 is outputrich and, upon completing the current cycle of the CFI, will cause theCFI to disable. With the CFI disabled, the input side of the transferdevice 8 continues to receive articles from the continuous motionconveyor. The CFI index enable sensor 206 senses when the transferdevice 8 has become input rich and then causes the CFI to be re-enabled.

[0198] The transfer device proximity sensing also includes a pair of INEOT and OUT EOT position sensors 204 and 210, respectively, fordetecting first and second end of travel limits of the transfer device8. When either the IN EOT position sensor 204 or OUT EOT position sensor210 detects transfer device travel beyond the limits, a softwareshutdown of the system is initiated. Beyond the end of travel sensorsare a pair of Input and output hardware limit sensors 201 and 202 whichmay include hardwired limit switches. If the transfer device 8 travelsbeyond either of the hardware limit switch sensors 201 or 202, themanufacturing system 2 is immediately shutdown.

[0199] Control of the transfer device 8 in response to the proximitysensors is further illustrated in the state diagram provided in FIG. 66.As illustrated, there is a CFI enabled state 778, a CFI disabled state780, and a line cycle stop 782. With the home position sensor 208detecting home position of transfer device 8, the CFI begins in theenabled state 778. When the CFI index disable position sensor 212detects an output rich condition 786, the system transitions to the CFIdisabled state 780 in which the CFI is turned off at the end of itscurrent cycle. Once the transfer device 8 returns to an input richcondition 788, the CFI index enabled position sensor 206 returns thetransfer device 8 to the CFI enabled state 778. In either the CFIenabled or disabled states 780 or 778, the system may enter the linecycle stop state 782 if either of end of travel position sensors 204 and210 detects extended travel of the transfer device 8 as shown in blocks790 and 792.

[0200] The relative movement of the transfer device 8 is illustrated inFIG. 67 as a function of percentage of transfer device travel and time.During normal operation, the transfer device 8 continuously receivesarticles of manufacture at its input side at a constant rate asdetermined by the continuous motion conveyor. The output side of thetransfer device 8 move in sync with the continuous feed indexer in anindexed intermittent motion. The indexed intermittent motion includesindex movement which is represented by the drop 794 in the sawtoothresponse and the continuous feed input movement during a dwell or CFIdisable is shown by the rise 796. The index travel movement generallyoccurs at a faster rate of speed than the continuous feed input motion.Accordingly, the transfer device 8 eventually becomes output rich, atwhich point the CFI is disabled and the transfer device travel is rampedback to the input rich condition, whereupon the CFI is then enabledagain.

[0201] Accordingly, the control system 600 provides distributedelectronic control e.g., “fly by wire control,” which is flexible andagile. The distributed control system 600 allows for high speed processmanufacturing such as battery manufacturing at rates achievable of atleast 900 to 1,800 batteries per minute. While the high speedmanufacturing system has been described in connection with a batteryapplication, it should be appreciated that the high speed manufacturingsystem 2 of the present invention may likewise by applied to variousother applications for manufacturing desired articles of manufacturewithout departing from the spirit of the present invention.

[0202] The above description is considered that of the preferredembodiment only. Modifications of the invention will occur to thoseskilled in the art and to those who make or use the invention.Therefore, it is understood that the embodiment shown in the drawingsand described above is merely for illustrative purposes and not intendedto limit the scope of the invention, which is defined by the followingclaims as interpreted according to the principles of patent law,including the Doctrine of Equivalents.

The invention claimed is:
 1. A transfer device for extracting articlesof manufacture from a trunk operating in a first mode of motion andtransferring the articles of manufacture for processing to a branchprocessing station operating at a second mode of motion and forreturning the processed articles of manufacture to the trunk, saidtransfer device comprising: a first portion having a first drive sourceoperating at said first mode of motion; a second portion having a seconddrive source operating at said second mode of motion; a conveyorassembly around said first portion and said second portion and supportedin an operative configuration for transporting articles of manufacturebetween said first portion and said second portion; and an accumulatingmember separating said first portion from said second portion andresponsive to said first mode of motion of said first portion thereofand to said second mode of motion of said second portion thereof.
 2. Thetransfer device according to claim 1, wherein said transfer device isarranged as a cruciform having a longitudinal axis and a lateral axis.3. The transfer device according to claim 1, wherein said accumulatingmember reciprocates along said lateral axis.
 4. The transfer deviceaccording to claim 1, wherein said conveyor assembly includes carriersat regularly spaced intervals therealong for carrying the articles ofmanufacture.
 5. The transfer device according to claim 1, wherein saidsecond mode of motion is an indexed motion comprising translating saidconveyor assembly one or more multiples of said regularly spacedintervals and alternating said conveyor assembly translation with apredefined dwell period.
 6. The transfer device according to claim 5,wherein an average speed of said second mode of motion is substantiallyequal to an average speed of said first mode of motion.
 7. The transferdevice according to claim 6, including a control element for controllingsaid second mode of motion and said dwell period of said second drivesource.
 8. The transfer device according to claim 7, further includingat least one sensor generating signals responsive to said reciprocatingelement motion and in communication with said control element.
 9. Thetransfer device according to claim 8 further including: a first drivepulley driven by said first drive source and in driving engagement withsaid conveyor assembly; and a second drive pulley driven by said seconddrive source and in driving engagement with said conveyor assembly. 10.The transfer device according to claim 9 further including at least afirst coupler adjacent to said first drive pulley and at least a secondcoupler adjacent to said second drive pulley for transferring of thebattery cans to and from said endless transport belt carriers.
 11. Thetransfer device according to claim 10, wherein each of said couplersfurther includes a rotatable circular dial having a periphery defining aplurality of regularly spaced pockets therearound for carrying thearticles of manufacture such that when said circular dial rotates inunison with motion of said transport belt, each of said pockets comes inlateral registration with a carrier on said conveyor assembly.
 12. Thetransfer device according to claim 11 further including: a stationaryfirst dead plate adjacent said first drive pulley and interposed betweensaid first drive pulley and said first coupler circular dial, said firstdead plate having a surface spaced a predefined distance from said firstdrive pulley to retain the articles of manufacture in each of saidcarriers as said conveyor assembly is driven by said first drive pulleyand further wherein said first dead plate dislodges the articles ofmanufacture from said first coupler dial for capture by one of saidcarriers on said conveyor assembly.
 13. The transfer device according toclaim 12 further including: a stationary second dead plate adjacent saidsecond coupler and interposed between said second coupler circular dialand said second drive pulley, said second dead plate having a surfacespaced a predefined distance from said second circular dial periphery toretain the articles of manufacture in each of said pockets as saidsecond circular dial rotates and further wherein said second dead platedislodges the articles of manufacture from said transport belt carriersat said second drive pulley for capture by one of said pockets on saidsecond coupler circular dial.
 14. A branch processing station for a highspeed manufacturing system for performing manufacturing processes onarticles of manufacture, said branch processing station comprising: acontinuous feed indexer including a transport mechanism for conveyingthe articles of manufacture along said branch processing station in anindexed intermittent motion wherein at least a portion of said transportmechanism is arcuate and conveys the articles of manufacture in anarcuate fashion, and further wherein each of the articles of manufactureis received by said transport mechanism at a single tangential pointalong said arcuate portion while said transport mechanism is in motion;and at least one process module mounted to said indexer for performingsaid at least one process on the articles of manufacture.
 15. The branchprocessing station according to claim 14, wherein the mass of saidtransport mechanism is approximately equal to or less than the mass ofthe articles of manufacture to be carried thereby.
 16. The branchprocessing station according to claim 14, wherein said transportmechanism further comprises: a conveyor; and a plurality of regularlyspaced carriers attached to said conveyor, each carrier having aretaining portion for holding and transporting an article of manufactureabout said indexer.
 17. The branch processing station according to claim16, further including an adapter having a first portion thereof engagedby each of said carriers, said engaged portion being interchangeablebetween any of said carriers and a capturing portion constructed tocarry a specific article of manufacture, said adapters permitting thereconfiguration of said system to carry different articles ofmanufacture by replacing at each of said carriers a first configuredadapter having a first capturing portion with a secondly configuredadapter having a second capturing portion.
 18. The branch processingstation according to claim 16, wherein said conveyor is a chain.
 19. Thebranch processing station according to claim 16, wherein said conveyoris a belt.
 20. The branch processing station according to claim 19,wherein said belt has a plurality of regularly spaced teeth about aninner periphery, and said regularly spaced carriers are positioned aboutan outer periphery of said belt, each of said carriers substantially inlateral registration with one of said teeth.
 21. The branch processingstation according to claim 20, wherein each of said carriers is fastenedto said belt with a removable pin thereby providing for replacement ofeach of said cleats without removal of said belt from said indexer. 22.The branch processing station according to claim 21, wherein said pinextends through said tooth parallel to a longitudinal axis of saidtooth.
 23. The branch processing station according to claim 14, whereinsaid indexed intermittent motion comprises a predefined translation ofsaid endless belt about said indexer alternating with a predefined timeperiod of dwell when said belt is not in motion.
 24. The branchprocessing station according to claim 16, wherein said predefinedtranslation of said endless belt is measured in one or more multiples ofintervals of said regularly spaced cleats.
 25. The branch processingstation according to claim 24, wherein said process module performs saidprocess during said dwell time period.
 26. The branch processing stationaccording to claim 14, wherein said indexed intermittent motioncomprises a predefined translation of the articles of manufacture aboutsaid indexer alternating with a predefined time period of dwell when thearticles of manufacture are not in motion.
 27. The branch processingstation according to claim 26, wherein said process module performs saidat least one process during said dwell time period.
 28. The branchprocessing station according to claim 27, wherein said process modulecomprises: a processing mechanism for performing said process on thearticles of manufacture; an engaging mechanism to place said processingmechanism in an operative position with respect to the articles ofmanufacture; and a control element for directing said engaging mechanismand said processing mechanism in a tasking sequence of placing saidprocessing mechanism in said operative position, directing performanceof said process by said processing mechanism, and disengaging saidprocessing mechanism from the article of manufacture.
 29. The branchprocessing station according to claim 28, wherein said control elementincludes a signal input for receiving a coordinating signal from saidmanufacturing system for performing said tasking sequence during saiddwell time.
 30. The branch processing station according to claim 29,wherein said process module further includes a base having apre-calibrated locating element.
 31. The branch processing stationaccording to claim 30, wherein said continuous feed indexer furtherincludes a process module mount receiving said base and saidpre-calibrated locating element such that said processing element can bereplaced with another like process module without requiring calibrationof said process module with respect to said indexer while mounted onsaid indexer.
 32. The branch processing station according to claim 31,wherein said engaging mechanism translates said processing mechanism tosaid operative position with respect to the article of manufacture whilethe article of manufacture is continuously retained by said transportmechanism during performance of said at least one process.
 33. Thebranch processing station according to claim 32, wherein said engagingmechanism extracts the article of manufacture from said transportmechanism, translates the article of manufacture to said operativeposition with respect to said processing mechanism, and returns theprocessed article of manufacture to said transport mechanism.
 34. Aprocess module for mounting to a high speed manufacturing system toperform a manufacturing process on articles of manufacture wherein thearticles are under control of the manufacturing system, said processmodule comprising: a chassis having a base; a processing mechanismmounted to an exterior of said chassis for performing a process on thearticles of manufacture; an acquiring mechanism to place the article ofmanufacture under control of said process module and to place saidprocessing mechanism in an operative position with respect to thearticle of manufacture for performing said process; and a controlelement associated with said chassis for directing said acquiringmechanism to gain control of the article of manufacture and fordirecting said processing mechanism in a tasking sequence of placingsaid processing mechanism in said operative position with respect to thearticle of manufacture, directing performance of said process by saidprocessing mechanism, and disengaging said processing mechanism from thearticle of manufacture to return control of the article to themanufacturing system.
 35. The process module according to claim 34,wherein said control element is responsive to an external coordinatingsignal from the manufacturing system for performing said taskingsequence during a predefined time period with respect to the conveyanceof the articles of manufacture along the manufacturing system.
 36. Theprocess module according to claim 35, wherein said process modulefurther includes a base with a pre-calibrated locating element such thatsaid process module can be replaced with another like process modulewithout requiring calibration of said process module with respect to themanufacturing system for mounting thereon.
 37. The process moduleaccording to claim 36, wherein said engaging mechanism translates saidprocessing mechanism to said operative position with respect to thearticle of manufacture while the article of manufacture is continuouslyretained by the manufacturing system during performance of themanufacturing process.
 38. The process module according to claim 36,wherein said engaging mechanism extracts the article of manufacture froma conveyor in the manufacturing system, translates the article ofmanufacture to said operative position with respect to said processingmechanism, and returns the processed article of manufacture to thebattery manufacturing system.
 39. The process module according to claim34 further including a micro-controller associated therewith toautomatically track and record a status and health of said processmodule.
 40. A processing conveyor system for processing articles ofmanufacture, said system comprising: a transport conveyor fortransporting the articles of manufacture from a beginning of said systemto an end of said system; at least one article segregator junctionintermediate said beginning and said end; an article segregator at saidarticle segregation junction for segregating said articles ofmanufacture from said transport conveyor; at least one articleintegrator junction downstream from said article segregator junction; anarticle integrator at said article integrator junction for integratingthe articles of manufacture onto said transport conveyor; and an articleprocessing conveyor between said article segregation junction and saidarticle integration junction.
 41. The conveyor system according to claim40, wherein said transport conveyor transports the articles ofmanufacture in continuous motion and wherein said processing conveyortransports the articles of manufacture in intermittent motion.
 42. Theconveyor system according to claim 41, wherein said article processingconveyor includes at least one article processing module therealong. 43.The conveyor system according to claim 42, wherein said processingmodule processes the article of manufacture during a dwell time of saidintermittent motion.
 44. The conveyor system according to claim 43further comprising a distributed control network including acoordinating controller for coordinating the processing of said articlesof manufacture, and at least one process station controller associatedwith each of said at least one article processing conveyor, said processstation controller controlling said at least one process to be performedon said articles of manufacture conveyed on said associated articleprocessing conveyor.
 45. The conveyor system according to claim 44,wherein said distributed control network further controls saidintermittent motion of said at least one article processing conveyor.46. The conveyor system according to claim 45, wherein said distributedcontrol network monitors the status of each article of manufacture andfurther monitors the position of articles on said at least oneprocessing conveyor for a position ready condition, said distributedcontrol network initiating a process operation on an article ofmanufacture according to a designated processing sequence upon detectingsaid position ready condition of said at least one processing conveyor.47. The conveyor system according to claim 41 further including a motionconverter intermediate said transport conveyor and said processingconveyor, said motion converter transitioning the motion of the articlesof manufacture between said continuous motion of said transport conveyorand said intermittent motion of said processing conveyor.